description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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FIELD OF THE INVENTION
The invention relates to a steel cord having a core strand and up to nine peripheral strands surrounding the core. Each strand comprises a center of one or more center filaments and two or more layers of filaments surrounding the center. Such a steel cord is often called a multi-strand steel cord.
A multi-strand steel cord may be used as a reinforcement of rubber products such as conveyor belts and heavy tires for off-the-road applications. Such a multi-strand steel cord may also be used as a hoisting cable or rope for applications in mines or elevators. Therefore, in what follows, no distinction will be made between the terms steel "cords", steel "ropes" and steel "cables".
A multi-strand steel cord is composed of high-carbon steel filaments of a suitable rod composition allowing high breaking loads to be reached. The steel filaments may be provided with a corrosion resistive coating such as a zinc or a zinc alloy or with a rubber adherable coating such as a copper alloy.
BACKGROUND OF THE INVENTION
Multi-strand steel cords must have a durable resistance to corrosion with a view to increasing their life span. Corrosion attack of the cords can be avoided not only by providing a suitable coating such as zinc but also by proper constructional features which allow rubber to penetrate between the individual steel filaments in the cord. Rubber penetration can be obtained by providing free spaces between the individual filaments. The situation with multi-strand steel cords is, however, not that simple as is the case with single-strand steel cords for the reinforcement of passenger or truck tires. A typical example of a multi-strand steel cord is a 7×19-construction. This steel cord has 133 individual steel filaments. Protecting every filament against corrosion attack means that every filament, even the center filaments of the core strand, should be enveloped with a rubber layer. As a consequence, relatively large spaces must be provided between neighbouring filaments. When providing large spaces between the filaments, however, the strands building up the cord and/or the cord structure itself loose their compact and uniform geometrical shape during embedment and, as a consequence, the cord no longer offers a uniform reinforcing level along its length. Moreover, it is always required that a certain given reinforcement level is achieved with the smallest possible volume of reinforcing material. This means that for a predetermined breaking load, the cross-sectional area of the steel cord should be as small as possible, which means that the outer diameter of each cord should be choosen as small as possible for a given steel section. It goes without saying that this requirement contravenes the above stated aim of providing relatively large spaces between neighbouring filaments in the cord.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a multi-strand steel cord with a adequate rubber penetration coupled with a maximum reinforcement degree.
According to a first aspect and to a first embodiment of the present invention, there is provided a steel cord having a diameter D and comprising a core strand and up to six peripheral strands which surround the core strand. The core strand has a diameter D1 and the peripheral strands have a diameter D2.
The ratio core strand diameter to peripheral strand diameter D1/D2 is greater than 1.05 and preferably smaller than 1.30. If D1/D2 is smaller than 1.05, an insufficient amount of rubber is able to penetrate between the peripheral strands to the core strand. If D1/D2 is greater than 1.30, a less uniform cross-section is obtained along the cord length.
Each strand comprises a center of one or more center filaments and two or more layers of filaments surrounding the center. All the filaments of each layer have substantially the same diameter. The filament diameter in each layer is preferably smaller than the total diameter of the center of the same strand. The filament diameter in a radially outer layer is also preferably smaller than the filament diameter in a radially inner layer of the same strand.
The twist angle of a radially outer layer is smaller than the twist angle of a radially inner layer of the same strand. The twist angle of a layer is within the context of this invention defined as follows. Suppose that d 1 is the (total) diameter of the center, that d 2 is the diameter of the filaments of the radially inner layer which immediately surrounds the center and that d 3 is the diameter of the filaments of a second layer surrounding the radially inner layer (=radially outer layer).
LL 2 is the lay length of the radially inner layer and LL 3 is the lay length of the radially outer layer.
The twist angle of the radially inner layer is defined as:
α.sub.2 =arctg[(d.sub.1 +d.sub.2)×π/LL.sub.2 ]×180/π
The twist angle of the second layer is defined as:
α.sub.3 =arctg[(d.sub.1 +d.sub.2 +d.sub.3)×π/LL.sub.3 ]×180/π
In case more than two layers surround the center structure, similar formulas can be used to determine the twist angle of a third and, possibly, a fourth layer.
Preferably, the difference in twist angle between a layer and an immediately underlying layer (=immediately radially inner layer) ranges between 1.5% and 20% of the twist angle of the immediately underlying layer, and most preferably this difference in twist angle is up to 10% of the twist angle of the immediately underlying layer. This arrangement of twist angles offers the advantage that filaments of an immediately radially outer layer do not tend to penetrate into the superficial helicoidally disposed interstices at the surface of the immediately radially inner layer, thereby blocking these interstices and preventing rubber penetration. Moreover, the arrangement of twist angles helps the formation of layers which are almost perfectly cylindrical in shape. The application of the larger angle in the radially inner layers also compensates for the inherently shorter filament lengths of the radially inner layers in comparison with the filaments in the radially outer layers. In this sense the arrangement of twist angles contributes to a regular distribution of the loading forces over all the filaments in the overall cross-section of the steel cord.
A first free space ranging from 0.0015×D to 0.0075×D, and preferably from 0.002×D to 0.007×D, is provided in at least the core strand between each pair of filaments of the radially most inner layer in order to enable the rubber to penetrate to the center filaments. Suitable absolute values of this first free space range from 0.010 mm to 0.075 mm. If the first free space has a value below the ranges mentioned, the chance for insufficient rubber penetration is great. If the first free space has a value above the ranges mentioned, too much volume will be occupied by the steel cord for a same predetermined breaking load.
A second free space being greater than the first free space, preferably ranging from 0.003×D to 0.015×D, and most preferably from 0.004×D to 0.012×D is provided in at least the core strand between each pair of filaments of the layer(s) surrounding the radially most inner layer. Suitable absolute values of this second free space range from 0.030 mm to 0.150 mm. The second free space must be greater than the first free space, since the second free space must not only allow the penetration of rubber in the layer(s) surrounding the radially most inner layer, but also the penetration of the rubber for the radially most inner layer and for the center. If the second free space has a value below the ranges mentioned, the chance for insufficient rubber penetration is great. If the second free space has a value above the ranges mentioned, too much volume will be occupied by the steel cord for a same predetermined breaking load.
The peripheral strands preferably have a preforming ratio ranging from 90% to 105%, e.g. from 93% to 100%. A preforming ratio of 97% is a good value.
The preforming ratio of the peripheral strands can be measured as follows. A predetermined length (e.g. 500 mm) of an assembled steel cord is taken and measured exactly. Next the peripheral strands are disentangled from the steel cord without plastically deforming the strands. The preforming ratio is determined as: ##EQU1##
All the layers of the core strand are preferably twisted in a first direction. The peripheral strands are preferably twisted around the core strand in this first direction, while the layers of the peripheral strands are twisted in a direction opposite to this first direction. This is done in order to promote a stable torsion balance.
The multi-strand cord according to the present invention may have following center structures:
(1) a single center filament;
(2) three filaments twisted around a straight, thin auxiliary filament which does not necessarily contribute to the final strength of the overall cord;
(3) two to seven filaments twisted with a twist angle which is greater than the twist angle of the overlying layer.
The diameter of the cord ranges from 3 to 20 mm, e.g. from 6 to 15 mm. The diameter of the steel filaments ranges from 0.15 to 1.20 mm.
The steel filaments may be provided with a copper alloy coating if adhesion to the rubber is a dominant factor, or with zinc or a zinc alloy coating if resistance to corrosion is a dominant factor.
Other embodiments of the first aspect of the present invention are as follows.
Up to five peripheral strands can be provided with a diameter D1/D2 ratio of at least 0.70, but with a maximum of 0.92.
Up to seven peripheral strands can be provided in the steel cord according to the invention with a diameter D1/D2 ratio of at least 1.39, but with a maximum of 1.69.
Up to eight peripheral strands can be provided with a diameter D1/D2 ratio of at least 1.73, but with a maximum of 2.10.
Up to nine peripheral strands can be provided with a diameter D1/D2 ratio of at least 2.07, but with a maximum of 2.45.
According to a second aspect of the present invention, there is provided a rubber product comprising at least one multi-strand steel cord according to the first aspect of the present invention. Rubber penetrates to the center filaments of the core strand and preferably envelops all the center filaments of the core strand. In this way a cord is obtained where all the individual steel filaments of the whole cord are surrounded by rubber.
The rubber product may be a conveyor belt or a tire for off-the-road applications.
According to a particular aspect of the invention, however, the rubber product is an elongated element with a substantially round cross-section and comprising only one multi-strand steel cord. The kind of rubber to be used depends on the eventual application. The rubber compound can be a suitable polychloroprene rubber having a fire resistance. The rubber compound can also be a nitrile rubber for freeze prevention and oil resistance or an EPDM rubber, i.e., an ethylene-propylene terpolymer, for an adequate weakening resistance and a low friction.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained in more detail with reference to the accompanying figures wherein
FIG. 1 shows schematically a cross-section of a multi-strand steel cord according to a first embodiment of the invention;
FIG. 2 shows schematically a cross-section of a rubber product comprising a multi-strand steel cord;
FIG. 3 illustrates the process of vulcanising a multi-strand steel cord;
FIG. 4 is a graph representing the rubber penetration in different cord structures;
FIG. 5 shows a test configuration for carrying out dynamic tests on cords or belts;
FIG. 6 shows schematically a cross-section of a multiple-strand steel cord according to a second embodiment of the invention;
FIG. 7 shows schematically a cross-section of a multiple-strand steel cord according to a third embodiment of the invention;
FIG. 8 shows schematically a cross-section of a multi-strand steel cord according to a fourth embodiment of the invention; and
FIG. 9 shows schematically a cross-section of a conveyor belt comprising a multi-strand steel cord.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, a multi-strand steel cord 10 according to the first embodiment of the invention comprises a core strand 12 and six peripheral strands 14 which surround the core strand 12.
The core strand 12 comprises a center filament 16 surrounded by a radially inner layer of six steel filaments 18 and by a radially outer layer of twelve steel filaments 20. The diameter of center filament 16 is greater than the diameter of filament 18 and the diameter of filament 18 is greater than the diameter of filament 20.
Each peripheral strand 14 comprises a center filament 22 surrounded by a radially inner layer of six steel filaments 24 and by a radially outer layer of twelve steel filaments 26. The diameter of center filaments 22 is greater than the diameter of steel filaments 24 and the diameter of steel filaments 24 is greater than the diameter of steel filaments 26.
In this way a so-called 7×19 multi-strand steel cord is obtained.
A first free space 28 is provided between neigbouring filaments 18 of the radially inner layer of the core strand 12. Such a first free space 32 may also be provided between neighbouring filaments 24 of the peripheral strands 14.
A second free space 30 is provided between neighbouring filaments 20 of the radially outer layer of the core strand 12. Such a second free space 34 may also be provided between neighbouring filaments 26 of the radially outer layer of the peripheral strands 14.
Multi-strand steel cord 10 can be manufactured according to following well known process steps:
a conventional drawing process, if necessary combined with the proper number of intermediate patenting steps;
a conventional galvanising process;
a conventional twisting process, e.g. by twisting first the individual strands followed by twisting the strands into the cord, this twisting can be done by means of a conventional tubular twisting machine or by means of a well-known double-twisting machine; the required degree of preforming of the peripheral strands may be obtained by subjecting the peripheral strands to a bending operation under a tensile force just before twisting.
Depending upon the choice of the wire rod and of the applied thermo-mechanical treatments, different levels of tensile strengths can be obtained for the different steel filaments of the steel cord. As a general rule, however, it can be stated that all filaments with the same diameter and which occupy the a similar place in the cord, have about the same tensile strength.
FIG. 2 shows the cross-section of an elongated rubber product which comprises a multi-strand steel cord 10 as described hereabove. Rubber 36 penetrates to every steel filament, even to center filament 16 of core strand 12. The circumferential circle of the cross-section of steel cord 10 is covered with a thin ply of rubber 36 so that an elongated element with a round cross-section is obtained.
As may noticed from FIG. 2, spaces are provided around almost every individual steel filament allowing rubber 36 to envelop almost every individual steel filament. This means that steel-to-steel contacts are practically excluded. In other words, fretting between steel filaments mutually is strongly reduced, which enhances the fatigue resistance of the composite rubber-cord, this will be illustrated below by way of an example.
A rubberised cord as shown in FIG. 2 can be used as a hoisting cable in mines or elevators, and particularly in those applications where a high resistance to corrosion and a high resistance to fatigue are required.
The elongated rubberised cord of FIG. 2 can be manufactured by a vulcanisation process which is illustrated in FIG. 3. A mould comprising an under part 38 and an upper part 40 gives the element its round form. A space 41 is provided as a passage for the rubber. A space 42 should be provided between the under part 38 and the upper part 40 in order to avoid that the upper part 40 contacts the lower part 38 and to create the required pressure. Rubber is applied to the cord 10 under a pressure of at least 30 kg/cm 2 at a temperature between 140° and 160° C.
Example 1
A 7×19 steel cord 10 according to the invention was built as follows:
cord diameter D is 9.83 mm
core strand 12: 0.85 mm (center filament 16)
(S-lay) +6×0.75 mm (filaments 18), twist angle 16.47°+12×0.69 mm (filaments 20), twist angle 16.14°
six peripheral strands 14: 0.69 mm (filaments 22)
(Z-lay) +6×0.61 mm (filaments 24), twist angle 11°+12×0.57 mm (filaments 26), twist angle 10.5°
cord: twist angle 17.88°, i.e. lay length of 66 mm, S-lay
The first space 28 of the core strand 12 amounts to 0.0259 mm and the second space 30 of the core strand amounts to 0.0706 mm. The ratio D1/D2 is 1.222. The weight of the cord per m is 323.8 g and the filling degree, i.e. the ratio surface of the steel section versus surface of the circumscribing circle corresponds to 54.4%.
This 7×19 steel cord according to the invention has been compared with a reference cord which does not have all features discussed above. The characteristics of the reference cord are as follows:
cord diameter D is 10.03 mm
core strand 12: 0.87 mm
(S-lay) +6×0.74 mm, twist angle 17.54° +12×0.71 mm, twist angle 21.82°
six peripheral strands 14: 0.71 mm
(Z-lay) +6×0.63 mm, twist angle 13.9°+12×0.58 mm, twist angle 14.95°
cord: lay length of 63 mm, S-lay
The first space in the core strand amounts to 0.038 mm and the second space in the core strand amounts to 0.0308 mm. The ratio D1/D2 is 1.204, the weight of the cord per m is 345.2 g and the filling degree corresponds to 52.8%.
As illustrated in FIG. 4, discussed hereafter, and despite a greater filling degree, the invention cord offers a much better rubber penetration than the reference cord.
A method and an instrument for measuring rubber penetration have been described in Belgian patent No. 1000162 (A6) of Applicant. Measuring results obtained with this method and instrument are shown in FIG. 4.
The pressure drop in function of the time for the invention cord 10 is represented by curve 44 and is in fact nihil for two different rubber compounds. This means that the spaces between the cord filaments are filled up completely.
In contradistinction herewith, the pressure drop is considerable for the reference cord, as is shown by curve 46 for a first rubber compound and even more clearly by curve 48 for a second rubber compound. This indicates the presence of cavities running along the helicoidal interstices between the filaments through which the air can pass thereby causing a substantial pressure drop. The above results are confirmed when examining the rubber penetration visually after cutting the cords out of the belt section. The different strands are untwisted from both the invention cord and the reference cord, and the filaments of each strands are also untwisted subsequently. Visual inspection of the invention cord allows to notice a substantial degree of rubber coverage even on the center filaments 16 and 22; this is not the case for the reference cord.
Example 2
An invention cord 10 is made as follows:
cord diameter D is 3.20 mm
core strand 12: 0.29 mm (center filament 16)
(S-lay) +6×0.26 mm (filaments 18), lay length 6 mm+12×0.24 mm (filaments 20), lay length 12 mm
six peripheral strands 14: 0.24 mm (filaments 22)
(Z-lay) +6×0.21 mm (filaments 24), lay length 7.5 mm+12×0.20 mm (filaments 26), lay length 15 mm
cord: lay length of 23 mm, S-lay
The naked (i.e. non rubberised) invention cord 10 and the cord after having been rubberised, i.e. vulcanised into a round elongated element 37, are now subjected to a test which is called the dynamic RPK test and which is illustrated in FIG. 5. The cord 10 or the round element 37 forms a closed circle around a driving drum 50, two fixed guiding rolls 52 and a roll 54. The driving drum 50 continuously changes its direction of rotation with a frequency of 120 changes per minute. A weight 56 of 1000N is attached to roll 54. The number of cycles before fracture is measured.
For the naked invention cord 80,000 cycles are measured before the first filaments break and 355,000 cycles are measured before the complete cord 10 breaks.
For the round elongated element 2,000,000 cycles are measured without noticing filament fractures and without noticing any drop in the residual breaking load.
This test confirms the above statements that rubber which envelops almost every individual steel filament along the entire length of the cord avoids the steel-to-steel contacts and considerably reduces the degree of fretting between the steel filaments, which results in an increased resistance against fatigue.
FIG. 6 shows a multi-strand steel cord 10 according to a second embodiment of the invention. The multi-strand steel cord includes the same features as the first embodiment, however, the center of each strand comprises three twisted filaments 58 enclosing a straight auxiliary filament 60.
FIG. 7 schematically shows a cross-sectional view of a third embodiment of the multi-strand steel cord according to the present invention. The multi-strand steel cord 10 also comprises a core strand 12 and six peripheral strands 14 in a similar manner as the first embodiment of the invention shown in FIG. 1, however, the center of each strand comprises two to seven twisted filaments. In FIG. 7 the center comprises three twisted filaments 62.
FIG. 8 shows a fourth embodiment of the invention. The fourth embodiment provides a multi-strand steel cord 10 with a core strand 12 and up to five peripheral strands 64.
FIG. 9 shows a schematic cross-sectional view of a conveyor belt 66 including a multi-strand steel cord 10 in accordance with the present invention. | A steel cord (10) has a diameter D and includes a core strand (12) and up to nine peripheral strands (14) surrounding the core strand. The core strand (12) has a diameter D1 and the peripheral strands (14) have a diameter D2. The ratio core strand diameter to peripheral strand diameter D1/D2 is greater than a predetermined value in order to enable rubber penetration. Each strand has a center of one or more center filaments (16, 22) and two or more layers of filaments (18, 20, 24, 26) surrounding the center. The twist angle of a radially outer layer is smaller than the twist angle of a radially inner layer of the same strand. A first free space (28) ranging from 0.0015×D to 0.0075×D is provided in at least the core strand between each pair of filaments (18) of the radially most inner layer. | 3 |
FIELD OF THE INVENTION
This invention relates to the field of computer networking, specifically to the establishment of secure connections between network entities on separate private networks.
BACKGROUND OF THE INVENTION
Businesses have a need for exchanging computer-based data with each other e.g., manufacturers need to order parts from suppliers vendors need the ability to maintain their products on customer networks, and management service providers need to maintain computing equipment on customer networks). Originally voice communications, facsimile, e-mail or direct contact was used to exchange such data. More recently, advanced network techniques have allowed parties to communicate more directly by dedicated computer networks, thereby eliminating more costly solutions.
The previously mentioned advanced networking techniques for business to business communications were achieved by establishing costly point to point private network links. Over time these point to point private networks have been displaced by more cost effective shared private networks. In many cases, shared private networks have been displaced by yet more cost effective virtual private networks over public networks.
As technology has moved business networking from private to shared private to virtual private networks, the reoccurring cost of the connection has decreased; however, new disadvantages have surfaced:
(a) persistent virtual private network connections take up a great deal of network resources; (b) persistent virtual private network connections are subject to more security concerns than private networks; (c) configuration and maintenance of virtual private networks require a great deal of administration on both participating private networks; (d) outsourcing of virtual private network configuration and maintenance has excessive capital and operational expenses.
SUMMARY AND OBJECTS OF THE INVENTION
Several objects and advantage of the present invention are:
(a) a method by which a directed circuit (leveraging a temporary virtual private network) may be established for exchange of application data between two network entities on separate private networks; (b) a method for actively managing and maintaining network apparatus on a private network via a network entity on a separate private network; (c) a method by which a directed circuit (in the absence of a virtual private network) may be established for passively monitoring network entities via network entities on a separate private network; (d) a method by which the establishing party of a temporary directed circuit may be authenticated and authorized; (e) a method by which the establishment of temporary directed circuits may be audited; (f) a method for expressing the rules associated with packet routing and network filtering on two separate private networks for the purpose of establishing directed circuits via more abstract policies; (g) a method of securely maintaining and implementing policies; (h) a method for implementing policies on either of the two private networks participating in the directed circuit; (i) a method for passing the ability to implement policies to a third party that may or may not diametrically participate in the directed circuit.
The present invention involves a private computer satellite network connected to a public computer network such as the Internet. The private computer satellite network can be the Local Area Network (LAN) of a business or organization. The satellite network is connected to the public network through a firewall. The local area network can have a plurality of network entities, such as personal computers and data servers/entities. The firewall is configured to allow the personal computers in the satellite network to send outgoing messages from the satellite network to the public network, and the firewall allows answer messages from the public network, which answer the outgoing messages, into the satellite network. In one particular embodiment the firewall allows the personal computers in the satellite network to access the World Wide Web through an HTTP connection protocol. This type of configuration for a firewall is very popular and accepted as being a minimal risk.
The present invention places a secure access appliance in the satellite network. This secure access appliance sends an outgoing message through the firewall, into the public network, and to a director, preferably a director computer network. An example of a director would be a vendor who is maintaining or servicing one of the data servers or personal computers in the satellite network. An example of an outgoing message would be a status message reporting on the status of the secure access appliance, and at least one of the personal computers or data servers in the satellite network. When the director needs access to the one data server in the satellite network, the director waits for the outgoing message from the secure access appliance. After the director receives the outgoing message, the director creates an answer message and sends the answer message back to the secure access appliance. The answer message includes data which asks the secure access appliance to create a tunnel connection, such as a carrier tunnel, with the director. Directed circuits are then created in the tunnel. Tunnel connections, carrier tunnels and directed tunnels are known in the art, and many different types of tunnel connections, carrier tunnels and directed circuits can be used with the present invention. Further description of the tunnelling technology is therefore not necessary to one of ordinary skill in the art.
Once the secure access appliance has created a secure tunnel with the director, the director can send instruction messages to the secure access appliance. These instruction messages can instruct the secure access appliance to communicate with the one data server inside the satellite network and what information to send to the data server/entity.
It is often preferred that the vendor servicing the one data server is not allowed to access information on other data servers or personal computers of the satellite network. Therefore the secure access appliance also has a network switch/router and a network filter to prevent the secure access appliance from communicating with forbidden network entities.
The secure access appliance is preferably installed with a set of rules of engagement which describe to who, and how, to communicate. These rules apply not only to how the secure access appliance communicates with other network entities in the satellite network, but also to whom, and how, the secure access appliance communicates through the firewall, through the public network, into the director network. These rules of engagement can be drawn up when the secure access appliance is installed. Therefore all, or at least most, changes to a satellite network for remote servicing can be incorporated into one network appliance in a secure manner. This provides for easy installation, and also secure communication. The operators and users of the satellite network do not need to worry about making a large number of changes to their network so that a vendor can service the network entities. The operators and users of the satellite network also do not need to worry that changes to parts of their satellite network for the secure communication could adversely affect other parts of the network and might make their satellite network less secure overall. This is especially true when several changes for different secure communication operations interfere with each other, and changes from obsolete or no longer needed secure communications are not completely removed.
The director network can also have a secure access appliance with rules of engagement. These rules of engagement would limit to who the director network could open a carrier tunnel with, and which of the personal computers in the director network could communicate with an open carrier tunnel. This then provides some protection for the director network from unauthorized entry, such as by messages posing as outgoing status messages from satellite networks.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of two private networks connected to a public network;
FIG. 2 is a schematic view of a satellite network with the secure access appliance installed;
FIG. 3 is a schematic view of two applications on separate private networks exchanging data via a directed circuit according to the present invention;
FIG. 4 is a schematic view of an active directed circuit established to actively manage an application on a private network;
FIG. 5 is a schematic view of a passive directed circuit established to passively monitor an application on a private network;
FIG. 6 is a schematic view depicting users of a management workstation authenticating and authorizing them with the present invention;
FIG. 7 is a block diagram depicting authentication and authorization objects and their relationships using the unified object-oriented methodology notation;
FIG. 8A is event flow diagram demonstrating the exchange of response and request information between an appliance and a controller according to the present invention.
FIG. 8B is a text diagram demonstrating a typical XML response document used for communicating state and status by an appliance to a controller according to the present invention.
FIG. 9 is a block diagram depicting configuration and status objects for domain appliances and passively monitored devices and their relationships using the unified object-oriented methodology notation;
FIG. 10A is event flow diagram depicting the establishment of a directed circuit and its sympathetic carrier tunnel in the case where the server (listening) appliance is the first to send a response;
FIG. 10B is event flow diagram depicting the establishment of a directed circuit and its sympathetic carrier tunnel in the case where the client (connecting) appliance is the first to send a response;
FIG. 10C is a text diagram depicting a typical XML request document used in requesting a change of state in a directed circuit by a controller with respect to appliance participating in the directed circuit;
FIG. 11 is event flow diagram depicting the establishment of a directed circuit in the presence of a suitable carrier tunnel established for another directed circuit;
FIG. 12A is event flow diagram depicting the sending of messages to an audit database as a result of establishing a directed circuit and/or its sympathetic carrier tunnel;
FIG. 12B is event flow diagram depicting the sending of messages to an audit database as a result of terminating a directed circuit and/or its sympathetic carrier tunnel;
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , two private networks 102 , 104 access a public network 100 . The first private or director network 102 uses a firewall 106 to allow a network entity 108 to freely initiate communications with other network entities accessed via the public network while blocking access to the entity 108 from the public network. The second or satellite private network 104 also uses a firewall 110 to allow a network entity 112 to freely access other network entities accessed via the public network while blocking access to the entity 112 from the public network. In this example, the network administrator of both private networks 102 , 104 do not trust any third parties to access their protected network entities 108 , 112 . The firewalls are configured to allow through answer messages from the public network which are answers to outgoing messages originating from inside the satellite network.
While the network administrators in this example do not trust each other with full access to their respective network entities, from time to time, they may need to exchange data with each other. Referring to FIGS. 2 and 3 , additional network apparatus in the form of secure network appliance 114 , 116 with directed circuit devices may be added to each private network to allow this interaction to take place. In the first private network 102 , the appliance 114 embodies a packet router, a net filter and a Virtual Private Network (VPN) server. In the second private network 104 , the appliance 116 embodies a packet router, a net filter and a VPN client. Provided that the firewall in the first (director) network 106 is configured to allow the passing of VPN connections and that both of the appliances 114 , 116 are correctly configured, a VPN session may be established between the two private networks 102 , 104 allowing the two networks to be joined.
While adding the appliance 114 , 116 to the solution provides the ability to temporarily join the two private networks 102 , 104 , either one or both network administrators may prefer to grant limited access to the other to carry out a more specific task. Since the appliances 114 , 116 contain packet filtering and packet routing as well as VPN technology it is possible for previously agreed upon terms of engagement to be effected as policies. Policies may then equate to routing, filtering and VPN rules used to configure those software components in the appliances 114 , 116 . By using this technique, it is possible for one network entity 112 on the second private network to be granted access to one and only one network entity 108 on the first private network. This technique provides a very specific form of access that is palatable to both network administrators since it maps back to their terms of engagement.
FIG. 2 shows different embodiments of the satellite network 104 . In these embodiments, the director network 102 needs to communicate with, or modify, the data entity 112 . Messages are sent during normal operation of the satellite network, between the personal computers 101 , the data entity 112 , and the public network 100 through a switch 103 . In one embodiment the secure access appliance 116 is a two port appliance and is placed between the switch 103 and the data entity 112 . In another embodiment, it is possible for the two port secure access appliance 116 to be placed between the firewall 110 and the switch 103 . It is still further possible for the secure access appliance to be a single port device, and only be connected to the switch 103 .
When the secure access appliance 116 is placed between the switch 103 and the data entity 112 , the secure access appliance 116 passes messages back and forth between the switch 103 and the data entity 112 normally. If secure access is desired, the secure access appliance 116 receives messages from the director network 102 and forwards these messages to the data entity 112 . If secure access is not desired, the secure access appliance 116 only passes normal messages back and forth.
If the secure access appliance 116 is a single port appliance, the secure access appliance 116 is passive when secure access is not required. When secure access is required, the secure access appliance 116 receives messages from the director network 102 , and then the secure access appliance 116 forwards those messages to the data entity 112 and only to the data entity 112 .
When the two port secure access device 116 is arranged between the firewall 110 and the switch 103 , the secure access device passes all the normal traffic between the firewall 110 and the switch 103 . When secure access is required, the secure access appliance 116 receives messages from the director network 102 via the VPN, and then the secure access appliance 116 forwards those messages to the data entity 112 and only to the data entity 112 .
The secure access appliance 116 contains structure that sets up the tunnel with the director network 102 , and also limits the secure access appliance 116 to only communicate with the director network 102 and the data entity 112 via the VPN. The packet router, net filter and VPN server of the secure access appliance 116 create the tunnel, the directed circuits, and limits the secure access appliance 116 to only communicate with permitted network entities. The secure access appliance 116 contains rules of engagement that are agreed upon ahead of time with the operators of the director and satellite networks 102 and 104 . These rules of engagement are then used to properly configure the secure access appliance.
While many features of the present invention can be created with a similar set of separate or existing routers, firewalls and VPN hardware on each of the private networks, such a solution requires potentially greater capital expense since more equipment is involved and certainly greater operational expense to configure and maintain the more abstract notion of policy in the form of specific configuration rules on multiple pieces of network apparatus. Thus one of the markedly distinguishing capabilities of the present invention is in the ability for the appliances 114 , 116 to effect policies in an automated fashion.
Traditional VPN deployments consist of a VPN server and multiple VPN clients. In such cases, the VPN server is typically realized as a piece of hardware or software running on a server within a network that end users need to access. Furthermore, the VPN client is typically a software application on the end-user's system which allows the end-user to access entities on the private network served by the VPN server.
The present invention utilizes network tunneling technology in a unique way. First, the traditional VPN model is reversed in that the protected network utilizes the client. Second, unlike the traditional VPN model, the client has the potential to represent multiple participating entities in that it resides in an independent network device. Finally, rather than being the typical point to point service, in the present invention, the tunnel serves as a carrier for a plurality of directed circuits.
Although traditional VPN technologies such as Point to Point Tunneling Protocol and IPSEC may be leveraged to form the carrier tunnel, essentially any tunneling technology may be used with respect to the present invention including proprietary methods. This is due to the fact that the carrier tunnel is part of a closed solution not intended to extend or leverage existing VPN deployments in any way. There are many different types of tunneling and many different ways of implementing tunneling and it is the notion of the carrier tunnel that is germane to the present invention. The actual tunneling technology utilized is left up to the person skilled in the art.
Referring to FIG. 3 , as noted above, the appliance 114 in the director network contains a tunnel server 122 . The appliance 116 on the second (satellite) network contains a tunnel client 120 . At this level, there is the potential for a carrier tunnel 118 to be established between the two appliances over the public network 100 . By introducing a network filter and packet router 126 on each appliance 114 , 116 it is possible to effect a directed circuit 124 that further refines the constraints of the tunnel 118 to suit the requirements of previously agreed upon previously established policies of engagement.
Referring to FIG. 4 , the establishment of directed circuits 124 and the sympathetic implementation of carrier tunnels 118 must be coordinated between two appliances. Much of this coordination is instigated by an additional component of the present invention referred to as a controller. The controller 128 is responsible for translating previously established policies of engagement into events that drive its internal state machine 130 . Ultimately, changes within the controller's state machine 130 are translated into requests which are communicated to the appliances 114 , 116 to effect changes in their respective distributed state machines components 132 .
Referring to FIG. 5 , before a directed circuit is established between two appliances, it would be beneficial for the controller 128 to be aware of the status of potential candidate network entities 112 for directed circuits. A special status or heartbeat message protocol is used to this end. In addition, to providing status information about the appliance 116 itself, an outgoing status or heartbeat message may also be used to convey information about entities 112 on the satellite network.
A protocol probe 136 on the remote appliance 116 will periodically send protocol requests 138 to a network entity 112 . Information collected by the probe will be stored in a protocol cache 140 . On a periodic basis, the heartbeat generator 142 will collect information about the state of the appliance 116 and information from the protocol cache 140 to build a heartbeat response. This response is an XML document that is transferred to the heartbeat monitor application 146 within the controller 128 via the HTTP protocol. The heartbeat monitor application 146 is then able to update the controller's database 148 with current information about the status of the remote application 116 and the remote network entity 112 . Subsequently, an end-user of the controller 128 may use a workstation 134 to access information from a remote network management proxy 152 on the controller 128 via a protocol request 150 .
Referring to FIG. 6 , since controller 128 offers the ability for an end-user to access potentially sensitive information about a remote network via their workstation 134 , it is prudent that end-users are required to authenticate themselves with the controller 128 and authorize their level of access. When end-users seek to use a workstation 134 to access the facilities of controller 128 and/or a local appliance 114 , they must first authenticate themselves via a user authentication application 156 on the controller 128 . The user authentication application 156 may then validate the user's credentials via a user authentication database maintained within the controller 158 (within here may also refer to symbolically within as in the case of a RADIUS server). Once the user is authenticated their level of authorization may also be established from previously defined rules of engagement. The end-user's controller session, the network address of the workstation 134 and any directed circuits may then be associated with each other and tracked for the duration of the end-user session without requiring additional authentication.
Referring to FIG. 7 , several objects are used within the controller to track end-user authentication. The UserBean 162 represents an end-user with rights on the controller. Each user may have many sessions with the controller with the potential of accessing the controller from multiple workstations at the same moment. Each of these sessions is tracked by a SessionBean 164 , which associates the session with the IP address of the workstation and the UserBean 162 . Each directed circuit is represented by a DirectedCircuitBean 166 . Each user may have many directed circuits. A session and/or a workstation's access to a given directed circuit is determined by the relationship of a UserBean 162 to its relationship with many SessionBeans 164 and many DirectedCircuitBeans 166 . Each carrier tunnel is tracked by a TunnelBean 168 . Each TunnelBean 168 is associated with many DirectedCircuitBeans 166 and each DirectedCircuitBean is associated with one TunnelBean 168 . Via these relationships directed circuits and their carrier tunnels are related back to the workstations used by them.
The controller must have a local appliance to participate in directed circuits. Since this appliance will typically listen for incoming tunnel requests, we refer to it as the server appliance. Referring to FIG. 8A , both the server appliance 114 and the client appliance 116 send heartbeat messages to the controller 128 on a periodic basis. Upon receipt of the heartbeat message, the controller 128 will respond with a request message.
Referring to FIG. 8B , the heartbeat response is represented by an XML document. This document consists of a single response element 170 . The response element 170 consists of a single domain element 172 which describes the domain or the network associated with the appliance sending the message. The domain element contains a single appliance element 174 and multiple device elements 180 . The appliance element 174 describes the appliance itself and may include a logs element 176 with many log entry elements 178 . The device element 180 describes a network entity that might participate in a directed circuit. A device element 180 may contain many protocol elements 182 which describe the state discovered by a protocol probe that may be of interest to an end-user in determining whether or not to establish a directed circuit to that entity.
Referring to FIG. 9 , several objects are used by appliances and the controller to represent the aforementioned response elements within their respective database and distributed state-machine components. The DomainBean 184 describes a domain and serves as an aggregation point for a single DomainStatusBean 190 and many ApplianceBeans 186 . While in the response protocol only one appliance is preferably associated with a given domain, a controller may associate many appliances with a given domain. The ApplianceBean 186 is an aggregation point for one ApplianceStatusBean 192 , many LogBeans 194 and many DeviceBeans 198 . The LogBean 194 is an aggregation point to many LogEntryBeans 196 which describe deltas to log entries on the appliance. The DeviceBean 198 describes a device that may potentially participate as a network entity in a directed circuit and serves as an aggregation point for a single DeviceStatusBean 200 and many DeviceProtocolBeans 202 . The DeviceProtocolBean describes the state of a particular protocol associated with the given device.
In a typical deployment end-users would not directly manipulate the controller; however, they would use a workstation running an application that interfaces with the controller. While it is not critical to the disclosure of the present invention, one might envision the end-user operating a WEB browser on their workstation that in turn is accessing a WEB interface on the controller. Referring to FIG. 10A , the workstation 134 would be able to request a directed circuit via the controller 128 interface. Once the directed circuit has been requested, subsequent outgoing status or heartbeat messages from the server 114 and client 116 appliances may be used to indicate that a directed circuit should be established. One of two scenarios may occur: server first or client first.
FIG. 10A shows the flow of data when the server appliance is the first to send a heartbeat after a directed circuit has been requested by the workstation to the controller 128 . In this case, the server 114 sends a heartbeat and receives a request to start a directed circuit 124 . This will put into effect the following chain of events on the server 114 :
Internal database is updated. Rules are applied to the net filter of the server 114 allowing the client/(secure access appliance) 116 at hand permission to establish a carrier tunnel 118 . Wait for the tunnel 118 to be established by the client 116 . Apply rules to the net filter allowing the carrier tunnel 118 to access the server side device 108 associated with the directed circuit 124 . Send a new heartbeat from the server 114 to the controller indicating that the directed circuit 124 has been established.
Next the client 116 sends its heartbeat and receives a request to establish a directed circuit 124 . This will put into effect the following chain of events on the client 116 :
Internal database is updated. Rules are applied to the net filter of the client 116 allowing the server 114 at hand permission to establish a carrier tunnel 118 . Initiate a carrier tunnel 118 with the server 114 . Tunnel 118 will be established immediately. Apply rules to the net filter allowing the carrier tunnel 118 to access the client side device 112 associated with the directed circuit 124 . Send a new heartbeat from the client 116 to the server 114 indicating that the directed circuit 124 has been established.
FIG. 10B shows the flow of data when the client secure access appliance 116 is the first to send a heartbeat after a directed circuit 124 has been requested by the workstation. In this case, the chain of events on the server 114 will be the same as above; however on the client side, the client 116 sends a second heartbeat and then receives its request to establish a directed circuit 124 . This will put into effect the following chain of events on the client 116 :
Internal database is updated. Rules are applied to the net filter allowing the server 114 at hand permission to establish a carrier tunnel 118 . Initiate a carrier tunnel 118 with the server 114 . Wait for the tunnel 118 to be established which will take some time. Apply rules to the net filter allowing the carrier tunnel 118 to access the client side device 112 associated with the directed circuit 124 . Send a new heartbeat from the client 116 to the controller indicating that the directed circuit 124 has been established.
Referring to FIG. 10C the request message 204 (which is sent to both the server and client, in response to a heartbeat) contains tunnel elements 206 . Each tunnel element may contain one or more directedCircuit elements 208 . The tunnel element 206 describes the parameters required to establish a carrier tunnel between the client and server. The directedCircuit element 208 contains additional parameters required to limit communications over that tunnel between a specific server side host and client side host. The same tunnel 206 and directedCircuit 208 elements will also be used in a heartbeat response to describe the current state of a pending directed circuit.
Again referring to FIG. 7 , two additional objects are used within the controller 128 and the client 116 and server appliances 114 to track the state of pending and active tunnels 118 and directed circuits 124 . The TunnelBean 166 represents a pending or active tunnel 118 . Each tunnel 118 may have many pending or active directed circuits 124 associated with it. The DirectedCircuitBean 168 is used to track the state of pending and active directed circuits 124 .
Referring to FIG. 11 , besides establishing a directed circuit between a client 116 and server 114 in the absence of a carrier tunnel 118 (as previously discussed), there is also the opportunity for a directed circuit 124 to be established that is able to leverage a previously established carrier tunnel 116 . As may be expected, this case is easier for both the client 116 and the server 114 . In fact, in this case, it does not matter which of the client 116 and server 114 sends the heartbeat first, and in both cases, the actions are the same:
Internal database is updated. Apply new rules to the net filter allowing the existing carrier tunnel 118 to access the local device 112 associated with the directed circuit 124 . Send a new heartbeat to the controller indicating that the directed circuit 124 has been established.
Referring to FIG. 12A it is possible for an additional network server referred to as an audit database 214 to be utilized in the logging of carrier tunnel and directed circuit events. Once the standard procedures for establishing carrier tunnels (as outlined above) have been completed and the controller 128 has been notified via heartbeats from both client 116 and server 114 that the tunnel has been established, the controller 128 will log a tunnel up event to the audit database 214 . Furthermore, once the standard procedure for establishing a directed circuit over a carrier tunnel (as outlined above) has been completed and the controller 128 has been notified via heartbeats from both client 116 and server 114 that the directed circuit has been established, the controller 128 will log a directed circuit up event to the audit database 214 .
Referring to FIG. 12B client 116 and server 114 appliance continue to send heartbeats to the controller 128 while carrier tunnels and directed circuits are established. Requests to bring down a directed circuit are delivered in this way. On either the client or the server, when a request is received to bring a directed circuit down, the following chain of events is initiated:
Internal database is updated. Rules are applied to the net filter blocking interaction between the carrier tunnel and the local host associated with the directed circuit. Send a new heartbeat indicating that the directed circuit has been closed.
Once the controller 128 has been notified by both the client 116 and server 114 that a directed circuit has been closed, the controller 128 will send a log directed circuit down message to the audit database 214 .
When the last directed circuit associated with a carrier tunnel is closed on either the client 116 or the server 114 , the following chain of events is put into motion:
Initiate closing of the carrier tunnel. Wait for the carrier tunnel to close. Delete previously established rules in the net filter which allowed the client to originally establishing a new tunnel to the server. Send a new heartbeat indicating that the carrier tunnel has been closed.
Once the controller 128 has been notified by both the client 116 and server 114 that a carrier tunnel has been closed, the control 128 will send a log tunnel down message to the audit database 214 .
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
REFERENCE NUMERALS IN DRAWINGS
100 —Public Wide Area Network (WAN)
101 —Personal computers in the satellite network
102 —First (director) private Local Area Network (LAN)
103 —Network switch in the satellite network
104 —Second (satellite) private Local Area Network (LAN)
106 —Firewall protecting director LAN
108 —Application on director LAN
110 —Firewall protecting second LAN
112 —Application on second LAN
114 —Server side appliance on director LAN.
116 —Client side appliance on satellite LAN.
118 —Carrier Tunnel
120 —Tunnel Client
122 —Tunnel Server
124 —Directed Circuit
126 —Network Filter & Router
128 —Controller
130 —State Machine
132 —Distributed State Machine component.
134 —Workstation
136 —Protocol Probe
138 —Protocol Request/Response
140 —Protocol Cache
142 —Heartbeat Generator
144 —Heartbeat Response/Request
146 —Protocol Filter
148 —Database
150 —Protocol Request/Response
152 —Protocol Proxy
154 —Web Browser
156 —Application Server
158 —Database
160 —Other Application
162 —UserBean—represents user record in database.
164 —SessionBean—represents user session in the database.
166 —DirectedCircuitBean—represents directed circuit in the database.
168 —TunnelBean—represents the carrier tunnel in the database.
170 —response element—body of the response packet
172 —domain element—describes the domain.
174 —appliance element—describes the appliance
176 —logs element—contains log entries of the appliance
178 —logEntry element—describes a delta of the log
180 —device element—describes a device in the domain
182 —protocol element—describes the results of a protocol probe.
184 —DomainBean—represents a domain in the database.
186 —ApplianceBean—represents an appliance in the database.
190 —DomainStatusBean—represents the status of a domain.
192 —ApplianceStatusBean—represents the status of an appliance.
194 —LogBean—represents a log of an appliance in the database.
196 —LogEntryBean—represents an entry in an appliance log.
198 —DeviceBean—represents a device in the database.
200 —DeviceStatusBean—represents the status of a device.
202 —DeviceProtocolBean—represents a protocol probe.
204 —request element—body of the request packet
206 —tunnel element—describe attributes of the carrier tunnel.
208 —directed circuit element—describes attributes of the DC.
210 —TunnelBean—represents the attributes of a carrier tunnel.
212 —DirectedCircuitBean—represents the attributes of a DC. | Creating directed circuits including encoding of policy and state information associated with directed circuits that may be established between two network entities on separate protected networks. The policies are maintained and implemented according to security methods that initially belong to network apparatus on either of the two protected networks; however the security methods may be relinquished to trusted third parties. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to a continuous laundry machine, more particularly for laundering batches consisting of unbundled items, the machine having a washing drum which is disposed in a casing at a distance from the casing inner wall and which is rotatable around its longitudinal axis and whose generated surface is formed with apertures for the passage of washing liquid and through which the laundry can be moved axially, in countercurrent to the washing liquid, by means of a convey or disposed inside the drum, the gap between the same and the casing being radially subdivided into outer pockets or chambers or the like to and from which washing liquid can be supplied and removed, possibly via pipes, such pockets or chambers or the like being disposed substantially symmetrically of an inner washing chamber or pocket of the radially subdivided drum.
The earliest models of machines of this kind had a horizontally inclined drum dipping into an open trough-like casing containing liquid at a constant level. Machines of this kind cannot provide different treatment zones each with its own washing conditions.
The casing therefore became drum-shaped and the gap between the casing and the drum was subdivided by annular ribs terminating at a distance from the drum, as disclosed for example by German Auslegeschrift No. 1,303,233. In this known washing machine the drum interior is also subdivided by annular ribs. Laundry is conveyed through the drum by means of conveying or entraining ribs and by means of a trough which has provision for limited axial movement. This known machine cannot provide complete separation between adjacent washing areas either.
To reduce this disadvantage the volume of the gap between the drum and the casing is reduced so that the most of the washing liquid is received by the drum. The result is still unsatisfactory, since optimum operation of a machine of this kind requires very precise separation and isolation between the discrete washing zones -- e.g. for cold prewash, hot prewash, boiling, hot rinse and cold rinse, so far as conditions such as temperature, addition of detergent and other additives are concerned.
Nor can these requirements be met by the washing machine disclosed by German Offenlegungsschrift 1,964,414. In this machine, comprising a closed drum without a casing, not only the discrete batches of laundry but also the discrete washing baths can be separated from one another; clearly, however, there cannot be separate control of the discrete baths and an appropriate supervision of temperature, detergent concentration, additive concentration etc. conditions.
A considerable disadvantage of the machines hereinbefore described is that they cannot be enlarged or reduced by one or more washing areas as may often be desirable for a variety of reasons.
If it is required to have this facility for amplifying the machine and to be able to have accurate separation of the items of laundry and of the baths, plus provision for reducing and maintaining particular conditions in the washing zone, the only solution of the problem is still to use a washing machine of the kind disclosed by German Patent Specification 1,130,403. The machine disclosed thereby does not have a continuous drum but a number of consecutive units completely separated from one another. The laundry is transferred from any washing unit to the washing unit which is adjacent as considered in the direction of conveyance by transfer means which take the form of scoop-like or shovel-like receptacles adapted to pivot around an axis extending transversely of the conveying direction. This machine has proved very satisfactory in practice because of the advantages just referred to, but the transfer of laundry between consecutive washing units often causes difficulties, for operating difficulties are bound to occur when moving conveyors of the kind described have to deal with an unwieldly material such as wet washing.
SUMMARY OF INVENTION
It is an object of the invention to improve the known washing machine, reduce the disadvantages thereof and to provide a washing machine of the kind of interest in the present context wherein there is precise separation or isolation of the discrete washing zones and very reliable conveyance of laundry between consecutive washing zones, so that the novel machine has the advantages of the known series laundry machine and the advantages of the known tubular laundry machine but has the disadvantages of neither. It is more particularly an object of the invention to enable the machine according to the invention to be enlarged or reduced very readily yet to provide a washing machine which, although having such a large number of advantages, is of rugged and reliable construction and of economic price.
According to the invention, therefore, the drum takes the form of discrete cylindrical segments, any two adjacent segments having directly contiguous end faces defined by a partition which extends substantially radially inside the drum the partition being formed with an aperture for the laundry to pass through. Each segment has a conveyor means for transferring the batch of laundry present in the particular segment concerned into the next segment. In order to seal off any two adjacent outer chambers a substantially radial flange extends outwardly from between two adjacent segments of the drum, into a gap between the drum and the casing and a rubbing seal is provided between such flange and the casing. In such a machine the discrete washing zones are therefore completely separated from one another, for not only are chambers or pockets formed in the gap by the flange sealed off from one another but adjacent washing areas inside the drum are completely separated from one another by the partitions, the laundry transfer apertures therein being disposed above the level of the liquid while washing is proceeding.
So that construction is entirely on the unit construction principle, preferably the casing too takes the form of discrete sections or portions which are each allotted to the drum segments, any two adjacent casing portions communicating with one another by way of their end faces. In this case, the end faces are disposed in spaced relationship to one another.
According to another preferred feature of the invention, a casing projection can be provided near the junction between two interconnected casing portions and a drum partition extends into such projection; preferably in this case, a substantially axially extending ring gasket is disposed at the outer edge portion of each partition and cooperates in sealing-tight manner with the two facing inside surfaces of the casing projections. Preferably in this case, a partition has on its outer edge an axially extending flange on whose outside the ring gasket is retained.
For mounting, the drum is preferably supported in an endless retaining element such as flat bands or belts or cables or chains or the like, thus making it unnecessary to have a continuous shaft or stub shafts at the drum ends, a factor which is very important so far as the unit construction idea is concerned.
It has been found that flat belts made, for example, of plastics material and having any plastics material or textile inserts, although theoretically suitable for the work, cannot withstand the continuous effect of washing liquid to the extent necessary or at least desirable for lengthy trouble-free operation; the retaining elements rotate at least to some extent in hot washing liquids and may be damaged or distorted etc. More particularly, they may experience different and permanent elongations which cannot readily be compensated for by the available adjustments.
However, according to the invention these disadvantages can be obviated very satisfactorily if the retaining means are flexible steel bands which have been made endless in some appropriate manner. Preferably in this case, an intermediate ring made of plastics material resistant to washing liquid, such as polyamide, is disposed between, on the one hand, a steel band serving as retaining element and, on the other hand, the associated axial flange of the particular partition concerned, the inner surface of such band engaging the outer surface of the intermediate ring. It has been found that these intermediate rings do not give rise to the difficulties associated with retaining elements in the form of flat belts, inter alia because the intermediate rings do not experience tension and so this factor alone obviates the very serious disadvantage of elongation. Also, materials unsuitable for flat belts or the like are available for such intermediate rings; for instance, such a ring can be made of a polyamide, very satisfactory results having been achieved, for example, with a RCG 1000 polyamide.
The intermediate rings preferably have their outer surface formed with a recess which is rectangular in cross-section and in which the steel band is disposed. Peripheral flange-like or collar-like webs therefore arise at the outside edges of the intermediate rings, so that the steel bands cannot run against the casing should they shift axially relative to the intermediate ring. To cope satisfactory with such a shift, which may occur because of unavoidable out-of-round conditions, for example, the width of the groove-like recess in the intermediate ring is greater than the width of the steel band, so that the steel band runs on a running surface which in normal conditions -- that is, when the band is running centrally -- has clearance on both sides.
Preferably, the axial width of the ring is greater than the width of the axial flanges of the partitions, to ensure adequate clearance between, on the one hand, the edges of the axial flanges and, on the other hand, the machine casing.
Conveniently too, the outer surface of each intermediate ring terminates at a distance from the machine casing, so that there is definitely no chance of the outer surface rising due to unavoidable inaccuracies.
Also, the intermediate rings provide sealing-tightness between adjacent segments, so the ring feature provides good separation or isolation between baths.
To provide a low-cost and reliable kind of drive for a washing machine of this kind without departure from the required unit construction principale, at least one drum-retaining element can cooperate with a drive mechanism. Very conveniently, the particular retaining element concerned or all the retaining elements is or are mounted on a shaft which extends axially above the drum. This feature solves not only the mounting problem but also the drive problem. Clearly, a washing machine of this kind can be enlarged fairly readily from, for example, eight washing zones to 10 or 12 washing zones. Very conveniently, a retaining element of this kind, in the form of a flat band for example, extends around the bottom edge of a partition, so that the drum is carried on the partitions. There are two advantages of this feature -- first, the retaining elements do not hinder the passage of washing liquid from the gap into the drum, and second the mounting is at the parts of the drum which are strengthened by the partitions, a feature which has advantages with regard to distortions of the drum under load.
In a preferred form of such a machine, the drum is mounted on a number of short axial shafts which are separate from one another and disposed above the drum and whose bearings are borne by the machine casing or by a stationary bearing construction.
This feature fits in very well indeed with the required unit construction principle and has still further advantages. For instance, a failure of any single drive of a short shaft will have little detrimental effect on machine operation since the motors are overdimensioned anyway for different reasons and in such a case can readily provide a correspondingly higher output for a short period.
Preferably, and as is apparent from the foregoing, a short shaft is associated with each segment; advantageously in this case, each short shaft is driven independently. Clearly, therefore, the motor units can be relatively small, with the further advantage that small motors are very easy to position and take up little space.
In a preferred form of such a drive for a short shaft, an electric motor drives vee belting which drives a pulley rotating solidly with the short shafts. In this case a reversing pulley for the particular endless retaining element concerned, preferably a flexible steel band, can be so disposed on the short shafts as to rotate solidly therewith. Very conveniently, each reversing pulley is secured to the hub of the vee-belt pulley which is disposed on the short shaft. The drive can then readily be adapted to a very wide variety of washing conditions and electricity consumption is very low since standard ungeared three-phase motors can be used. This is advantageous since geared motors are relatively costly and require servicing and make considerable noise, which is ergonomically undersirable.
Another advantage of the drive construction just described is that the short shafts are substantially torque-free since the driving torque is, as it were, applied to the shaft externally and does not, as is the case with a continuous shaft, have to be transmitted via the shaft for the whole drum. Consequently, shaft diameters can be smaller and costs are therefore reduced.
For efficient frictional engagement between the reversing pulleys and the steel bands are to ensure very reduced slip, the reversing pulleys preferably having a friction lining on their outside generated surface.
It has been found that a washing machine of this kind, more particularly when it has a large number of segments and is of a corresponding length, forms a structure which cannot of course be inherently rigid. This arises, if for no other reason, from the various assembled-together components, more particularly the consecutive segments etc. -- and some out-of-roundnesses etc. are unavoidable.
Preferably, to deal with this factor yet to provide a very reliable and long-lived construction, according to the invention the reversing pulleys for the retaining steel bands are each disposed on a substantially horizontal rocker which extends at right angles to the machine longitudinal axis, the rocker being mounted at one end for pivoting around a horizontal axis and having a resilient mounting at its other end. This feature helps to compensate for mis-alignments of various kinds and provides very effective interception and attenuation of impacting caused by the laundry while it is being washed and conveyed. Preferably, the rockers each take the form of two parallel arms between which a reversing pulley is disposed, each arm of a rocker being adjustable vertically, by pivoting around its pivot axis, and horizontally, independently of the other arm.
Preferably, each rocker is mounted resiliently by means of a single spring element on the machine casing or on the machine bearing construction; preferably, the spring element can also act as a damper.
Preferably, the pivot axes and therefore the resilient mounting or bearing positions of adjacent rockers are horizontally offset by 180° from one another so as to provide compensation for the torque loading of the bearing places on the drum. Correspondingly, of course, the driving motors are disposed alternately on opposite sides of the machine.
Preferably, each washing-chamber (segment) conveyor takes the form of an inclined and sinuously extending chute between a surface of one partition of the chamber and the aperture in the other partition of the chamber. British Patent Specification 516,772 shows an arrangement of this type. In this case, the geometric development of the chute can comprise a part circular portion bounded, for example, by a secant, the distance between the secant and the arcuate portion being less than the radius of the circle; and a triangular portion which joins the circle portion at one corner and which is disposed inside the circle area, one side of the triangular portion being disposed on the secant and being shorter than the same.
A helical chute portion is therefore provided which extends from a surface of one partition of a segment or washing chamber towards the laundry aperture in the other partition of such chamber, the top corner of the sinuously extending chute extending to an edge portion of the laundry aperture concerned, such portion being disposed at the drum surface. The exposed edge of the helical chute portion, such edge not being contiguous with the other partition, communicates with the laundry aperture in the first partition by way of the triangular portion which extends to the helical chute and to the drum longitudinal axis and via which laundry is conveyed for transfer between adjacent washing zones. Preferably, one exposed edge of the triangular portion merges directly with one edge of the laundry aperture, which is preferably a sector of a circle while the other exposed edge of the triangular portion is physically exposed at an inclination to the longitudinal axis or, may, alternatively, merge into another triangular chute portion disposed substantially at right-angles to the first triangular chute portion. Conveniently, the sector angle of such a laundry aperture is less than 180° and is preferably approximately 60° , to leave a large enough aperture for the laundry to pass through and to ensure adequate separation between adjacent washing zones during washing.
To provide the motions necessary both for washing and conveyance, a reversible drive is provided, the conveyor conveniently being disposed at the top of the drum during washing while the drum reciprocates. The drum then makes a single revolution in a direction determined by the conveyor, whereafter reversing washing can be resumed.
Preferably, to achieve intensive washing during washing phases, there is a substantially axially extending rib-like projection on the inside of the segments, on the portion not occupied by the conveyor. It has been found that a single such projection is sufficient to provide an intensive mechanical washing effect.
In cases where the finished laundry is delivered over end, not only does the finished laundry issue from the drum end face right at the bottom of the final drum segment or chamber but there is also an undesirable discharge of water, such discharge occurring even when the drum is not conveying, but just washing or remaining stationary.
Preferably, to obviate this the drum narrows funnel-fashion at its delivery end, that is, the internal diameter of the drum decreases towards the delivery end. A helical conveyor in the form of a deflector is provided in the funnel-shaped terminal portion of the drum and serves to eject the laundry from such portion after washing. This feature provides the required, as it were, abrupt delivery or discharge of a batch of laundry. However there is no appreciable discharge of water since, due to the funnel-shaped construction, the edge portion of the delivery orifice may be, for example, some 300 to 400 mm above the lowest part of the drum chambers in the non-tapering portion of the drum.
Preferably, to ensure a desired and possibly predetermined tensioning of the drum-retaining elements, at least one tensioning element is provided for the retaining elements. Preferably, and more particularly if the retaining element is in the form of a belt or a flat band, the tensioning element can take the form of a tensioning roller or jockey, two oppositely disposed tensioning elements possibly being associated with each retaining element.
According to another preferred feature of the invention, a sensor for operating one or more switches, conveniently electrical contacts, at one or more vertical settings of the drum can be provided at least on a partition near an end part of the machine. The switches can serve to ensure, for instance, that the machine can be started only when it is at a required setting.
Another possibility is that the length of the endless retaining elements is such that when such elements are in the untensioned state, that is, when the machine is not operating, the drum bears on the inside of the casing. No load is therefore applied to the retaining elements unless the machine is in operation and so, inter alia, the working life of the retaining elements is considerably increased.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:
FIG. 1 shows a side elevational view, partly in section and in simplified form, of part of a continuous laundry machine in accordance with the present invention,
FIG. 2 shows a section through the machine of FIG. 1 on the line II--II,
FIG. 3 shows a diagrammatic view in side elevation of part of the drum and of drive shaft and of the piping supplying air to the reciprocating actuators for the tensioning elements,
FIG. 4 shows a view corresponding to FIG. 2, in highly diagrammatic form, in section on the line IV--IV of FIG. 3,
FIG. 5 shows a view to an enlarged scale of details of the zone V disposed inside chain-dotted framing in FIG. 3, the zone V representing a drive shaft mounting or bearing zone,
FIG. 6 shows a view to an enlarged scale, in section on the line VI--VI of FIG. 4, of a link support for suspension of the tensioning elements,
FIG. 7 shows a view to an enlarged scale of an alternative form of the portion III framed by chain-dotted lines in FIG. 1;
FIG. 8 shows a simplified view, partly in longitudinal section, of part of a drive mechanism of another machine in accordance with the present invention,
FIG. 9 shows a diagrammatic simplified plan view of the front end portion of the machine part of which is shown in FIG. 8, in simplified form;
FIG. 10 shows a transverse sectional view, in diagrammatic form, of part of the machine of FIG. 8, the drum segments or chambers being mounted on rockers as in the construction shown in FIG. 5,
FIG. 11 shows a sectional view on the line VII--VII of the part shown in FIG. 10,
FIG. 12 shows a simplified front elevational view, looking in the direction of the arrow VIII of FIG. 13 of the delivery end of the washing machine part of which is shown in FIG. 8, and
FIG. 13 shows a simplified and diagrammatic plan view of the front end portion of the drum shown in FIG. 8, looking in the direction of the arrow IX of FIG. 12.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 of the drawings shows part of a continuous laundry machine for laundering laundry (not shown). For the sake of clarity the drive, the mounting system and the connecting piping between the various washing zones is omitted from FIG. 1.
As can be seen in FIG. 2, the machine has a casing 1 which is, in cross-section, substantially part-circular. A washing drum 3 is disposed at a distance a from casing inner wall 2, and a reversible drive 6 can rotate drum 3 about its longitudinal axis 4 in the direction indicated by an arrow 7 (FIG. 2) and in the opposite direction. Approximately 75% of the generated surface of drum 3 is formed with apertures for washing liquid. As will be described in greater detail hereinafter, a conveying facility fixedly mounted inside drum 3 is adapted to move the laundry therethrough in countercurrent to the washing liquid.
The drum 3 comprises a plurality of discrete cylindrical segments, only five -- 3a, 3b, 3c, 3d and 3e -- are shown in FIG. 1. Any two adjacent segments, such as 3a and 3b or 3b and 3c, are separated by a partition 9. Of the partitions 9, only two partitions 9a, 9b can be seen in FIG. 1 and only the partition 9b can be seen in FIG. 2. Each segment 3a to 3e has its own conveying facility which will be described in greater detail hereinafter.
The gap between the casing inner wall 2 and the outside of the drum 3 is subdivided radially into chambers 11a, 11b, 11c and so on which are substantially completely sealed off from one another. To this end, the partitions 9a, 9b each extend radially beyond the segments 3a to 'e. At their outer edge the partitions 9a, 9b have an axially extending flange 12. A flat belt 13a, 13b, 13c, 13d engages with the radially outer surface of the flanges 12 and extends upwardly from the particular flange concerned, as can be seen in FIG. 2, to engage with a drive shaft 14 at the top of the machine. The belts 13a to 13d are endless.
As can be gathered from FIG. 1, the casing 1 is combined from discrete portions 16a to 16e which are associated with the corresponding drum segments or washing chambers 3a to 3e. Any two adjacent portions, such as 16a and 16b or 16b and 16c and so on are interconnected by way of adjacent flange portions 17. The flange portions 17 are spaced apart by spacers 18 in the form of curved flat metal members which have a sealing composition on the edges thereof adjacent the surfaces of the flange portions 17. The flange portions provide a casing projection near the junction between any two interconnected casing portions 16a, 16b or 16b, 16c and so on, and as FIG. 1 shows, a respective partition 9a, 9b etc. of drum 3 extends into such projection. Sealing-tightness between any two adjacent outer chambers 11a, 11b or 11b, 11c and so on is achieved by means of the belts 13a to 13d which engage with the flanges 12 of the partitions 9. The edges of the belts 13a to 13d each cooperate to provide sealing tightness with the two facing inner surfaces of a casing projection that is, with those faces of the flange portions 17 which are adjacent one another, to provide a sliding or rubbing seal.
As well as providing sealing tightness between adjacent chambers 11a, 11b or 11b, 11c etc. the belts 13a to 13d also serve for the mounting of the drum 3 and participate in the drive thereof, as will be described in greater detail hereinafter with reference to FIG. 2.
For the drive of the drum 3, an electric motor 19 drives, via a vee-belt 21 and a pulley 22, the drive shaft 14 with which the belts 13a to 13d are in frictional engagement. As can be seen in FIG. 2, rollers 23 keep the belts 13a to 13d in engagement with the flanges 12 of the partitions 9. Also, rollers 26 movable in the direction of the arrows 24 engage the outside of the belts 13a to 13d, so that it is a simple matter to align the drum 3.
Each drum segment or chamber 3a to 3e has a respective conveying facility 27a, 27b, 27c and so on extending from a closed part of one partition, such as 9b, to a laundry aperture 28a, in the partition 9a, of a segment 3b. Basically, the conveyors 27a, 27b and 27c take the form of inclined sinuously extending chutes. The chutes are each produced from a sheet of material taking the form of a segment of a circular disc. The main portion of each chute is formed by bending the segments to form helical portions 29a, 29b, 29c etc. which are fitted in corresponding chambers or segment 3a to 3e. The sheets of material from which the chutes are produced also each comprise a triangular portion one side of which is defined by only part of the length of the chord of the segment. The triangular portion is disposed within a circle which would be formed by a continuation of the arc of the segment. After assembly the triangular portion forms an inclined chute 31b or 31c, as will be apparent from a consideration of FIGS. 1 and 2. The chutes 31b, 31c are disposed in the respective chambers or segments of the drum 3 at an inclination to the longitudinal axis and one edge of the chute (formed by an edge of the triangular portion) merges with the non-partition-contacting edge of a corresponding helical portion 29a, 29b 29c etc. Another edge of the triangular portion 31b, 31c meets an edge of a corresponding laundry aperture 28a, 28b whilst the other edge of the triangular portions 31b, 31c join onto another triangular portion 32b, 32c which extends substantially perpendicularly to the first triangular portion 31b, 31c in the particular drum segment concerned.
The laundry apertures 28a, 28b substantially resemble sectors of circles and have a sector angle of approximately 60°, as can be seen from FIG. 2.
A substantially axially extending rib 33a 33b, 33c is disposed on that portion of the inside of the drum segments 3a to 3e which is not occupied by the conveyor 27a, 27b, 27c.
As shown in FIG. 2, pipes 34 are connected to the outer chambers 11a, 11b, 11c and, liquid control boxes 36 are provided at the free ends of the pipes 34.
As shown in FIG. 2, the drive 6 and the drive shaft 14 are mounted on a frame 37 which extends down to the stationary part of the machine, that is, to the casing 1. The casing 1 has legs 38 for supporting it on the foundation.
FIGS. 3 and 4 are very diagrammatic side elevational views of the washing machine, more particularly of the casing, with the omission of a large number of items and with particular emphasis on the drum 3 and the drive shaft 14. As can be gathered from FIG. 4, the retaining elements 13, which take the form of flat belts, are each associated with two tensioning elements in the form of jockeys 26 (also diagrammatically indicated in FIG. 2). The jockeys 26 are disposed opposite one another. They are suspended on a cross-member of the frame 37 by means of link suspensions 41 and the two rollers of each pair are interconnected by a reciprocating actuator 42, the devices 42 being pneumatically operated and being described in greater detail hereinafter.
As shown in FIG. 6, the bottom end portion of the link suspensions 41 which retains the jockeys 26 takes the form of a clevis 43. So that the belts 13 can move past the jockeys 26 and the actuators 42 in the manner shown in FIG. 4 (and FIG. 2), the actuators 42 are each connected to the associated clevis 43 in the manner shown in FIG. 6.
As can be seen in FIG. 3, a number of actuators 42 are connected to a common pressure source, symbolized in FIG. 3 by an arrow 44, half of all the actuators 42 being combined to form a first group so far as pressure medium supply is concerned, each of the two actuator groups which are visible in FIG. 3 having an inlet valve 46 and an outlet valve 47 for the pressure medium.
Disposed on each of the partitions 9 is a sensor 48 adapted to operate a number of electrical contacts at adjustable vertical settings of the drum 3.
The length of the belts 13 is such that, when they are not in tension, the drum 3 bears on the casing inside 2, so that there is no load on the belts 13 when the machine is inoperative.
FIG. 5 shows a bearing zone of shaft 14, supplementing the diagrammatic view of FIG. 3. The drive shaft 14 consists of portions interconnected by flange couplings 49. Correspondingly, the portion 14' visible in FIG. 5 has part of a coupling at each of its two ends and is mounted in two bearings 51 carried on a cross-member of the frame 37. A guide roller 52 rigidly connected to the portion 14' the shaft 14 is disposed between the two bearings 51 and has at its two lateral boundary surfaces edges 53 to ensure positive guidance of the belts 13 on the roller 52.
The lower part of FIG. 6 shows a cover 54 for the casing 1, the cover 54 preventing vapours, sprayed liquid and the like, from discharging upwardly or to the outside. As will be apparent, the belt 13 extends through the cover 54, then engages with drum 3 in the manner shown in FIGS. 2 and 4.
In FIG. 7, which shows the part of the machine framed in chain-dotted lines in FIG. 1, the belts 13 take the form of flexible steel bands, an intermediate ring 56 being disposed between each steel band 13 and the associated axial flange 12, the ring 56 being made of a plastics material resistant to laundry liquids, such as a RCH 1000 type polyamide. The inner surface of the steel band 13a engages with the outer surface of the ring 56.
The ring 56 is formed on its outer surface with a rectangular cross-section groove-like recess 57 which is adapted to receive the band 13a, the width B of the recess being greater than the width b of the band 13. Also, the overall axial width B + 2e of ring 56 is greater than the width D of the flange 12, with the result that there are clearances d between the casing 1 and the flange 12; consequently, even if the partition 9a experience impacting because of unavoidable production inaccuracies, misalignments, sagging or the like, it cannot contact the casing 1. For the same reason the outer surface of the ring 56 terminates at a distance i from the casing 1 or from the spacer 18 rigidly secured thereto, thus obviating the risk of grazing.
The machine is devised correspondingly so far as the partitions 9b, 9c and so on are concerned.
The bands 13 are made of non-rusting steel. They are very advantageous, since the washing liquid does not attack them and they experience virtually zero elongation as a result of the weight of the drum 3 and its contents. In cooperation with the associated ring 56, the result is not only excellent suspension of the drum 3 but also a sealing of the washing baths on both sides, since there can be no appreciable exchange of liquids through the gaps 58 between the ring 56 and the portion 59 forming part of the casing 1.
This feature also satisfies the requirements for steel construction since, for example, the drum partitions 9 may readily suffer from misalignments without causing disturbances in operation or even damage to the machine. The bands 13 have limited provision for axial reciprocation, for example, because of different loading conditions of the drum, without any risk of disturbances arising.
FIGS. 8 to 11 shows part of a machine having a different drive mechanism. FIG. 10 is a simplified view of the drive mechanism corresponding to the top part of FIG. 2 but with many items omitted, since it is the mounting which will be particularly described with reference to FIG. 10. As shown in FIG. 10, the belts 13 indicated merely by a chain-dotted line in FIG. 10, are flexible steel bands 13 which reverse over a respective pulley 61 disposed above the drum 3. Each pulley 61 is secured to a substantially horizontally extending rocker 62 which is disposed at right-angles to the drum longitudinal axis and whose construction is basically apparent from FIG. 11. The rocker 62 of each drive unit is pivotally mounted at one end 63 on the frame 37 and can therefore pivot horizontally. At its other end 64 the rocker 62 is resiliently mounted.
As shown in FIG. 11, each rocker 62 mainly comprises two parallel arms 66, 67 between which the associated reversing pulley 61 is disposed. Each arm 66, 67 of each rocker 62 is vertically and horizontally adjustable independently of the other arm 67, 66. To this end, adjusting screws 68 provided in the end portion 64 of each rocker 62 enable the pivoted position of the particular rocker arm 66 or 67 concerned to be adjusted relatively to a cross-member 69. The screws 68 are then locked by nuts 71. This feature provides very satisfactory adjustment of true running of the drive elements to be described hereinafter. Each cross-member 69 is secured by screws 72 to a connecting section member 73, the same therefore interconnecting all the mounting or bearing positions and providing adequate stability for the complete system and precluding simultaneous different vertical deflections.
Horizontal adjustment can be provided by appropriate adjustment of the associated bearing 74 for the rocker arm concerned on the frame construction 37; FIG. 10 only shows the bearing for the arm 66. The resilient mounting for each rocker 62 takes the form of a single resilient and damping element 76 which bears on the frame 37 and which may be, for exmple, a metal-to-rubber bonded device.
The drive mechanism shown purely in diagrammatic form in FIG. 10 is dash-triple-dotted lines, will now be described in greater detail with reference to FIGS. 8 and 9. Drum 3 is suspended on a number of short shafts 14' whose bearings 77 are carried on the frame 37. The shafts 14' serve not only for the mounting or suspension of the drum 3 but also for the drive of the machine, as will be described hereinafter.
Each drum segment or chamber 3a to 3e has one such short shaft 14' associated with it, each such short shaft being driven independently.
Each shaft 14' is driven by an independent electric motor 19 by way of vee-belting 21 and a pulley 22 (see FIG. 8) secured to shaft 14' so as to rotate therewith. Also similarly secured to each shaft 14' is the associated reversing pulley 61 for the associated steel band or the like 13, each reversing pulley 61 being secured to the hub 78 of the belt pulley 72 as can be seen in FIG. 8. The outer surfaces of the pulleys 61 have a friction lining 79 to ensure a satisfactory frictional engagement between the pulley 61 and the steel band 13.
As can be gathered from the very simplified view given in FIG. 9 which is a diagrammatic plan view of the front portion of the machine, the motors 19 are disposed in alternate relationship on either side of the construction 37, and so the rockers 62 are each horizontally offset by 180° with respect to one another, so that the pivot axes at the rocker ends 63 and the resilient elements 66 at the rocker ends 64 are correspondingly each alternately offset from one another by 180°.
The arrangement which has been described with reference to FIGS. 8 to 11 provides outstandingly quiet operation even for prolonged periods despite the steel construction and the large number of interconnected and in some cases moving parts, since the arrangement permits excellent settings and adjustments being made while the complete apparatus is being run-in. Also, electricity consumption is very low since the motors 19 are simple and rugged three-phase motors and since they cooperate with belt drives, that is, no geared motors or the like are used. Also, failure of a single motor does not entail stoppage of the complete apparatus, which can continue to run at least until termination of the washing programme. Also, the driving forces are applied in such a way that the diameter of the shafts 14' can be much less than if a single continuous shaft were to be used.
Basically, however, and as shown in FIG. 11, a continuous shaft can be used. Conveniently, in this case, universal shafts (not shown so as not to overload the drawings) are provided for the individual portions of the shaft 14.
FIGS. 12 and 13 show simplified views of the discharge or exit and 81 (see FIG. 9) of the machine, the drum 3 narrowing funnel-fashion at its delivery or discharge end. The funnel-shaped portion 82 of the machine has a helical conveyor 83 (not shown in FIG. 13 so as not to overload the drawing). The batches of laundry which have been washed are delivered by the conveyor 83, as it were abruptly, from the drum portion 82 but without any appreciable discharge of washing liquid, since the level of the washing bath is lower than the lowest point 84 of the funnel-shaped portion 82.
The operation of the machine will now be described.
Laundry for washing is introduced, by means of a feeder (not shown), into a first segment or chamber of the drum 3; the first segment is not shown in FIG. 1 and is disposed at the right-hand end of the drum 3. The first segment can be used, for example, for soaking. Washing is then given by reversing rotary or pivoting movements around the drum axis 4, the angle of rotation or pivoting being less than 360°.
After a predetermined time or after a number of reversing rotary movements corresponding to a predetermined time, the drum 3 makes one complete revolution in the direction indicated by the arrow 7, the angle of rotation being more than 360°. The laundry batch concerned, just like the laundry batches disposed in the other segments or chambers 3a to 3e reaches the inside of the helical portion 29a, 29b, 29c of the corresponding conveying facility 27a, 27b, 27c and is conveyed onwards by sliding on the helical portion 29a, 29b, 29c in the direction indicated by the arrow 39, the laundry passing onto the chute portion defined by the triangular portion 31b, 31c, thereof and then passing therefrom through the laundry aperture 28a, 28b in the respective partition 9a, 9b into whichever segment is the next as considered in the direction of the arrow 39.
The next segment can, for instance, still form part of the soaking zone or form part of the prewash zone. This segment can then be followed by, for example, multi-segment washing zone for the main hot wash, which can be followed by another zone for hot rinsing and finally a cold rinse zone.
Depending upon circumstances and requirements, any particular zone can be omitted or an extra segment can be added to any particular zone or a segment removed therefrom. Consequently, a washing programme using five washing zones may, for example, be carried out in a machine the drum of which has a total of from 5 12 12 segments and a corresponding number 16a to 16e of casing portions.
As will be apparent from the foregoing description and from the drawings, each of the discrete outer chambers 11a, 11b, 11c is completely sealed off from the others, thus making it possible to specify and maintain very accurately the conditions in each washing zone without the interchange conditions in the border regions extending as far as the central part of any wasing zone. For instance, a temperature of 70° C can be maintained very accurately in one washing zone, whereas in the next zone the temperature can be 90° C. Similarly, washing conditions in respect of the addition of detergents and additives can be maintained within very defined conditions in the machine according to the invention. The complete laundering operation can therefore be kept under much better control than it can be with known washing machines, with the final result of better laundering.
The washing ribs 33a, 33b, 33c, by their mechanical washing effect, provide a very effective contribution to the washing action. It has been found that just a single rib 33a, 33b, 33c is sufficient to produce an excellent result.
Also, during the reversing washing movement the drum 3 is in such a position that the conveying facilities 27a, 27b, 27c are mainly uppermost, the rotating of pivoting movement occurring around this position.
The provision of jockeys 26, reciprocating actuators 42 and sensors 48 makes it possible, so far as the starting, operation and run-out of the machine described more particularly with reference to FIGS. 1 and 6 are concerned to provide the following cycle of operations:
When the machine is inoperative, no compressed air is supplied from the source (arrow 44 in FIG. 3) and so there is no pressure in the air line and actuators 42. The drum 3 is borne by the casing 1 and does not load the retaining elements 13.
At switch-on the two air inlet valves 46 are operated electrically, with the result that compressed air is supplied uniformly to all the pistons of the actuators 42. Drum 3 is therefore raised, because of the restriction caused by the jockeys 26, until reaching its operative position. The sensors 48 are operated in the operative position. Only after the sensors 48 have been operated is the drive 6 for the drive shaft 14 and therefore for starting actual laundering operative. Simultaneously, the inlet valves 46 close automatically. Consequently, the drum 3 is disposed, when it starts to be driven, in a horizontal position, the tension of all the belts 13 being substantially identical.
To alter the relative height of the drum 3 with respect to the casing 1 because of impressed forces or pulses which arise in laundering, more particularly because of laundry dropping off the rib 33, a minimum-maximum-control (not shown) which does not form part of the invention is provided.
For instance, if the initially empty drum 3 drops as it is loaded, due to the belts 13 stretching, to a level below the required operating position, contacts operated by the sensors 48 open either one or both inlet valves 46 until the drum 3 has been restored to its operative position. The converse occurs when the drum 3 is emptied slowly. Slow emptying might of course lead to the drum 3 rising excessively, and in this case when the required permissible maximum height is exceeded one or both outlet valves 48 open so that the drum 3 sinks until it has been restored to the required operating position.
The outlet valves 47 are operated when the machine is stopped so that the drum 3 drops into the inoperative position previously described.
Clearly, the operation hereinbefore described ensures automatic alignment of the machine over a wide variety of loadings, and the fact that the belts 13 are loaded uniformly and have no load on them when the machine is inoperative ensures that they have a long working life. Also, the automatic height control, which is operative not only at start-up but throughout laundering, provides a damping effect which has advantages so far as the transfer of dynamic bearing forces to the surrounds is concerned. Yet another advantage is that the construction of the suspension and of the tensioning means can provide considerable compensation for mis-alignments of the partitions which cooperate with the endless belts.
The machine according to the invention, as well as being reliable in operation, rugged, of simple construction and therefore of economic cost, offers more particularly and readily the possibility of enlarging or reducing the casing 1 by one or more segments 3a to 3e and portions 16a to 16e and so this unit construction feature always ensures optimum adaptation to individual circumstances. | The invention relates to a laundry machine comprising a washing drum which is rotatable about its longitudinal axis; the generated surface of the drum being formed with apertures through which washing liquid can flow. The drum is supported, preferably by an endless retaining element, such that an outer surface of the drum is spaced apart from an inner surface portion of a casing. At least one partition extends substantially radially inside the drum thereby dividing the drum into discrete segments. The partition has an aperture and conveyor means are disposed inside the drum for conveying laundry from one segment of the drum to an adjacent segment thereof via the aperture. A flange extends substantially radially outwardly from the drum, and from between each pair of adjacent segments thereof, thereby dividing the gap between the drum and the casing into pockets or chambers, means being provided for obtaining a fluid-tight seal between each flange and the casing. Washing liquid may be fed to each pocket or chamber between the drum and the casing via respective pipes communicating therewith. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/982,509, filed Aug. 30, which application is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The principles disclosed herein relate generally to wound closure by facilitating stretching of skin tissue. More specifically, the disclosure relates to a system and method of facilitating expanding the skin tissue over a wound by use of dynamic force.
BACKGROUND
[0003] Surgical procedures such as tumor removal or fasciotomies can result in large skin wounds. Chronic wounds such as diabetic ulcers frequently do not heal. Techniques have been developed to facilitate the wound closure of large skin defects and chronic wounds.
[0004] Common methods for closure of wounds and skin defects include split thickness skin grafting, flap closure and gradual closure utilizing tissue expansion. A split thickness skin graft involves removing a partial layer of skin from a donor site, usually an upper leg or thigh, and leaving the dermis at the donor site to re-epithelialize. In this manner, a viable skin repair patch can be transferred or grafted to cover the wound area. The graft is often meshed, (which involves cutting the skin in a series of rows of offset longitudinal interdigitating cuts) allowing the graft to stretch to cover an area two or three times greater than the wound, as well as provide wound drainage while healing. Normal biological function of the skin heals the cuts after the graft has been accepted. A meshed graft of this type requires a smaller donor area than a conventional non-meshed or full thickness skin graft. Flap closure involves transferring skin from an adjacent region to the wound. This technique is only effective in anatomical regions that are amenable to transfer of adjacent skin. It is also a more complex surgical procedure involving increased surgical costs and risks. Both of these methods do not provide optimal cosmesis or quality of skin cover. Other disadvantages of these methods include pain at the donor site, creation of an additional disfiguring wound, and complications associated with incomplete “take” of the graft. In addition, skin grafting often requires immobilization of the limb, which increases the likelihood of contractures. The additional operation and prolongation of hospital stay is an additional economic burden.
[0005] Gradual, or progressive, closure is another method of wound closure. This technique may involve suturing vessel loops to the wound edge and drawing them together with large sutures in a fashion similar to lacing a shoe. In addition, the wound edges may be progressively approximated with suture or sterile paper tape. The advantages of this gradual, or progressive, technique are numerous: no donor site is required for harvest of a graft; limb mobility is maintained; superior cosmetic result, more durable skin coverage, better protection because skin is full thickness, and maintenance of normal skin sensation may all be achieved.
[0006] Existing devices for effecting a gradual closure, however, have many disadvantages. Current methods and devices rely on static ribbon or suture material which must be repeatedly readjusted in order to draw wound edges together because a relatively small skin movement substantially eliminates much of the closure force. Even with constant readjustment, maintenance of near constant tension over time is difficult, if not impossible, to achieve. Since widely used existing closure techniques involve use of relatively inelastic materials such as sutures or surgical tape, a substantial amount of tension is put on the wound edges during periodic adjustment to obtain the necessary closure force. Excessive tension may cut the skin or cause necrosis due to point loading of the tissue.
[0007] What is needed in the art is a gradual wound closure technique that is self-regulating and self-adjusting and uses continuous or dynamic tension to draw the wound edges together, without obstructing the wound, thus eliminating the need for constant readjustment involved with the static systems.
SUMMARY
[0008] The principles disclosed herein relate to wound closure by facilitating stretching of skin tissue. The disclosure relates to a system and method of facilitating expanding the skin tissue over a wound by use of dynamic force.
[0009] The disclosure is directed to a wound closure system including components adapted to apply a dynamic tension force on a plurality of anchors that are attached to skin tissue surrounding a wound. The dynamic tension force draws the anchors toward the wound facilitating stretching of the skin tissue over the wound area.
[0010] In one particular aspect, the disclosure is directed to a wound closure system comprising a plurality of skin anchors mechanically attached to external skin tissue around a generally linear wound. The skin anchors are configured to pass a line extending between multiple skin anchors across the wound. A single line or multiple lines may be used. Application of tension to the line(s) draws the skin anchors toward each other and toward the wound. The tension is applied by a tensioning apparatus that is mechanically attached to the external skin tissue.
[0011] In another particular aspect, the disclosure is directed to a wound closure system comprising a plurality of skin anchors mechanically attached to external skin tissue on opposite sides of a generally linear wound, a line extending between the skin anchors to slidably connect the anchors, the line slidably engaged with at least one skin anchor, and a biasing member that provides tension on the line to draw the connected skin anchors toward each other and toward the wound.
[0012] In an alternate embodiment, the disclosure is directed to a wound closure system comprising a skin anchor mechanically attached to external skin tissue on a first side of a generally linear wound, an anchorable tensioning apparatus mechanically attached to external skin tissue on an opposite side of the wound, a line extending between the skin anchor and the tensioning apparatus to movably connect the anchor to the tensioning apparatus, the line fixedly engaged with the anchor, with the tensioning apparatus providing tension on the line to draw the skin anchor and the tensioning apparatus toward each other and toward the wound.
[0013] In yet another particular aspect, the disclosure is directed to a method of closing a wound, the method comprising the steps of mechanically attaching a skin anchor to external tissue on a first side of a generally linear wound, mechanically attaching an anchorable tensioning apparatus to external skin on an opposite side of the wound, extending a line between the skin anchor and the tensioning apparatus to movably connect the anchor to the tensioning apparatus, and providing tension to the line to draw the skin anchor and the tensioning apparatus toward each other and toward the wound.
[0014] In yet another particular aspect, the disclosure is directed to a wound closure kit comprising a skin anchor adapted for attachment to external skin tissue, a line adapted to be coupled to the skin anchor, an anchorable tensioning apparatus adapted for attachment to external skin tissue and adapted for providing tension on the line.
[0015] In yet another particular aspect, the disclosure is directed to an alternative use of the wound closure system where the wound closure system may be used for cosmetic purposes to stretch the skin at certain parts of the body that do not include wounds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a top perspective view of a wound closure system in accordance with the principles of the present disclosure, illustrating multiple stretching elements operably positioned in relation to a wound;
[0017] FIG. 2 is a top perspective view of one stretching element of FIG. 1 illustrated alone, the stretching element having a skin anchor and an anchorable tensioning apparatus;
[0018] FIG. 3 is an exploded view of the tensioning apparatus of the stretching element of FIG. 2 ;
[0019] FIG. 4 is an enlarged top perspective view of a biasing member of the tensioning apparatus of FIG. 3 ;
[0020] FIG. 5A is a top perspective view of a spool of the tensioning apparatus of FIG. 3 ;
[0021] FIG. 5B is a bottom perspective view of the spool of FIG. 5A ;
[0022] FIG. 5C is another bottom perspective view of the spool of FIG. 5A ;
[0023] FIG. 6 is an enlarged top perspective view of a base of the tensioning apparatus of FIG. 3 ; and
[0024] FIG. 7 is a top perspective view of an alternative embodiment of a wound closure system in accordance with the principles of the present disclosure, the wound closure system illustrated in combination with a cross-sectional view of the skin.
DETAILED DESCRIPTION
[0025] The inventive aspects of the disclosure will now be described by reference to the several drawing figures. The functional features of the inventive aspects can be embodied in any number of specific configurations. It will be appreciated, however, that the illustrated embodiments are provided for descriptive purposes and should not be used to limit the inventions described herein.
A. Wound Closure System
[0026] FIG. 1 illustrates a wound closure system 10 having features that are examples of inventive aspects disclosed herein. The wound closure system 10 illustrated in FIG. 1 includes a plurality of stretching elements 120 (each individually indicated as 120 a , 120 b and 120 c ) generally positioned around the periphery of a wound 12 . Elements 120 a , 120 b , 120 c , etc. are attached to the skin surrounding wound 12 by mechanical means (e.g., staples). Each element 120 includes an anchor 125 (each individually indicated as 125 a , 125 b , 125 c ) and an anchorable tensioning apparatus 140 (each individually indicated as 140 a , 140 b , 140 c ). Anchors 125 a , 125 b , 125 c are connected to anchorable tensioning apparatus 140 a , 140 b , 140 c by a tension line 130 (individually indicated as 130 a , 130 b , 130 c ).
[0027] A single stretching element 120 , having anchor 125 , line 130 and anchorable tensioning apparatus 140 , is illustrated in FIG. 2 . For ease of understanding, the inventive aspects of the following disclosure will be described with reference to only a single stretching element, it being understood that multiple elements can be utilized for the wound closure system within the spirit of the invention, as illustrated in FIG. 1 .
[0028] Referring to FIG. 2 , anchor 125 is connected to anchorable tensioning apparatus 140 by tension line 130 , which is fixedly attached to anchor 125 and to tensioning apparatus 140 in a manner as to extend across wound 12 (as illustrated in FIG. 1 ). Anchorable tensioning apparatus 140 , which is attached to skin at the opposite side of the anchor 125 , is adapted to apply tension to line 130 to draw anchor 125 and the tensioning apparatus 140 inwardly toward each other, and, thus, the skin over the wound. Anchor 125 and tensioning apparatus 140 are positioned to generally linearly move toward each other.
[0029] An inelastic or non-stretchable line 130 is preferably used to draw skin anchor 125 and the tensioning apparatus 140 toward wound 12 since the tensioning apparatus 140 is adapted to provide the dynamic force needed for wound closure. An elastic line 130 can also be used, and may be preferred in some embodiments due to its ability to provide lessened tension and more flexibility.
[0030] In an alternate embodiment that is within the scope of this disclosure, an elastic line 130 alone that is fixedly attached to two anchors located on opposite sides of a wound can be used to provide the dynamic tension on the skin, without the use of a tensioning apparatus.
B. Anchorable Tensioning Apparatus
[0031] Referring to FIG. 3 , tensioning apparatus 140 includes a base 160 , a spool 180 that seats on the base 160 , a biasing member 150 that is placed around the spool 180 , a connection rod 190 that extends axially through the tensioning apparatus 140 , and a cover 170 that is placed on the base 160 to enclose the individual components of the tensioning apparatus 140 .
[0032] Referring to FIG. 4 , there is generally illustrated therein an enlarged view of the biasing member 150 of the tensioning apparatus 140 . The biasing member 150 is adapted to be mounted within tensioning apparatus 140 to provide the dynamic tension force on the skin anchor 125 . As the skin stretches and grows over wound 12 , anchor 125 moves toward apparatus 140 and toward wound 12 , reducing the tension on line 130 and creating “slack” on tension line 130 . Biasing member 150 provides the tension to take up the slack on line 130 . In certain embodiments, the tension force that is applied to each skin anchor 125 is usually at least 1 oz. and usually no greater than 64 oz., commonly between 4 and 16 oz.
[0033] The biasing member 150 is depicted essentially as a spring formed from a coiled-up metal band 151 . Although depicted as a coiled spring in FIGS. 3 and 4 , biasing member 150 may include other structures. For example, biasing member 150 may include a constant-force spring designed to provide a constant level of tension on line 130 when it is in a loaded state. Biasing member 150 may alternatively include a nonconstant-force spring designed to provide varying amounts of force on line 130 depending upon how tightly it is wound. As one skilled in the art will appreciate, the force application characteristics of such springs depend upon factors such as the mechanical properties of the springs, the thickness, the diameter, etc.
[0034] It will be understood that biasing member may also refer to an elastic tension line that is extended across the wound and coupled to two skin anchors on opposite sides of the wound that is used to draw the anchors toward each other and toward the wound.
[0035] The band 151 defines an inner hook portion 152 and an outer tab portion 153 .
[0036] The coiled up band 151 is positioned around an upper spring mount portion 182 of the spool 180 (see FIGS. 5A-5C ) as will be discussed further below. When positioned as such, a portion of the hook portion 152 of the band 151 is placed within a slot 188 defined on the upper spring mount 182 of the spool 180 . The outer tab 153 of the band 151 cooperates with the cover 170 of the tensioning apparatus 140 to stay fixedly in a wound orientation.
[0037] Referring to FIGS. 5A-5C , there is generally illustrated the spool 180 of the tensioning apparatus 140 . The spool 180 includes an upper spring mount portion 182 , a lower tension line mount portion 184 , and a main plate 186 separating the two portions. In this embodiment, all the portions of the spool 180 are depicted as integrally formed from one unitary piece. However, it will be appreciated that in other embodiments, the spool may be formed from multiple separate pieces that are coupled together.
[0038] The upper spring mount portion 182 has a generally cylindrical shape. The upper mount portion 182 includes a slot 188 adapted to receive the hook portion 152 of the biasing member 150 as discussed above. The spool 180 also includes a throughhole 106 for receiving the connection rod 190 used to couple the spool 180 to the base 160 of the tensioning apparatus 140 .
[0039] The lower tension line mount portion 184 defines a winding groove 185 . The winding groove 185 is defined between the main plate 186 and a lower seat plate 183 . The lower seat plate 183 provides structure for seating the spool 180 into the base 160 of the tensioning apparatus 140 . The spool 180 also defines a line attachment hole 187 that communicates with the winding groove 185 through a slit 189 defined within the winding groove 185 . Before being wound, one end of the tension line 130 is fed through the slit 189 into the hole 187 and a knot is tied to secure one end of the tension line 130 to the spool 180 , the knot being large enough that the end of the line 130 will not slip through the slit 189 . After being secured to the spool 180 , line 130 is wound around the spool 180 within the winding groove 185 .
[0040] Referring to FIG. 6 , there is generally illustrated the base 160 of the tensioning apparatus 140 . Base 160 includes a generally circular main body 161 . Defined within the body 161 is an interior cavity 165 shaped to receive the lower seat plate 183 of the spool 180 . The base 160 includes a hole 164 defined within the interior cavity 165 for receiving the connection rod 190 used to couple the spool 180 to the base 160 .
[0041] Referring back to FIG. 3 , there is generally illustrated therein the cover 170 of the tensioning apparatus 140 . The cover 170 generally includes an interior shape configured to fit around the exterior of the base 160 . The cover 170 includes a main body portion 171 and an elongate snout portion 172 . The main body portion 171 fits over the main body portion 161 of the base 160 .
[0042] The interior of the cover 170 (not shown in the FIGS.) is generally shaped and sized to receive the biasing member 150 . The interior of the cover 170 includes structure (not shown in the FIGS.) that cooperates with the outer tab portion 153 of the biasing member 150 to keep the biasing member wound up within the cover 170 .
[0043] The snout portion 172 of the cover 170 includes a hole for feeding an end of the tension line 130 out of the cover 170 , the other end of the tension line having been attached to the spool 180 located within the cover 170 . The front of the snout portion 172 includes an extended lip 175 which defines a ramped surface 176 . The ramped surface 176 is configured to cooperate with a tension line tab 128 of a skin anchor 125 to fixedly mount the cover 170 to a skin anchor 125 . As shown in FIG. 3 , the ramped surface 176 is inserted within a tension line slot 129 defined by the tension line tab 128 of the skin anchor 125 as the tension line tab 128 abuts against the front of the snout 172 . With this feature, the tensioning apparatus 140 can be allowed to move with the anchor 125 as the skin is stretched toward the wound 12 .
[0044] It will be appreciated that, although the tensioning apparatus is depicted as a unit that is separate from the skin anchor that it is attached to, the tensioning apparatus may include an integrally formed anchoring means adapted to anchor the tensioning apparatus to external skin.
C. Skin Anchors
[0045] As seen in FIG. 1 , anchors 125 a , 125 b , 125 c are placed around the periphery of wound 12 . Each anchor 125 is mechanically fastened to the skin, such as by conventional medical skin staples. Suturing can also be used to mechanically attach anchors 125 to the skin.
[0046] Referring to FIG. 2 , two skin anchors 125 of the stretching element 120 are generally illustrated therein. Each anchor 125 includes a first end 121 , a second opposite end 123 , and a generally rectangular body 124 defined between the first end 121 and the second end 123 . The anchor 125 includes two skin-penetrating barbs 122 proximate the first end 121 for securement to the skin. The barbs 122 preferably have a bearing surface with a large enough width perpendicular to the direction of the tension so that the barbs 122 do not cut through the skin when pulled toward the wound 12 in tension. In this manner, as the barbs 122 move in toward the wound, the skin moves with the barbs 122 . The barbs 122 can be bent at an angle A B less than about 90 degrees from the skin surface. The barbs 122 can be bent, preferably, at about a 60 degree angle A B to improve their ability to hold into the skin. The edges of the barbs 122 are sharp to make it easy to penetrate the skin upon insertion. Two pairs of indentations, generally indicated at 126 , are formed on opposite sides of the body 124 of the anchors to help guide where mechanical attachment, such as staples 102 , are to be placed. Two pairs of tabs 127 extending out from the opposing sides of the body 124 are adapted to abut against the staples 102 to pull the skin toward wound 12 . Although the guiding indentations 126 are located forward of the tabs 127 , as anchor 125 is pulled in toward wound 12 , the tabs 127 eventually abut against the staples 102 after initial stretching of the skin around the wound area is achieved.
[0047] The tension line tab 128 defines the tension line slot 129 formed at the first end 121 of the anchor 125 for receiving tension line 130 . The tension line slot 129 is formed with a wide lead-in area to make it easy to receive tension line 130 . The tension line slot 129 may be sized such that tension line 130 is “snapped-in” past the narrowest point of the slot 129 to prevent the line from accidentally being pulled out.
[0048] Still referring to FIG. 2 , anchor 125 includes a length L A . The barbs 122 include a penetration depth D P . The inner edges of the barbs 122 are spaced apart a distance of W B . The dimensions, L A , D P , W B , and A B can be varied according to desired skin anchor performance in different parts of the human body and for different types and ages of skin.
[0049] Table 1, below, illustrates two example configurations for the anchor, with two different sets of dimensions that are suitable for use with the stretching element 120 . Anchors with example configuration 1 are preferably retained by two conventional regular size medical skin staples (5.7 mm×3.9 mm). Anchors with example configuration 2 are preferably retained by two wide size medical skin staples (6.9 mm×3.9 mm).
[0000]
TABLE 1
Anchors (unless otherwise specified, all dimensions are in inches)
L A
D P
W B
A B
Configuration 1
0.739
0.158
0.186
60°
Configuration 2
0.607
0.115
0.206
60°
[0050] In a preferred embodiment, the anchor 125 is formed from stainless steel sheet such as 302 or 316 containing 8 to 14% nickel content. It will be appreciated that the anchors can be stamped with a progressive die, wire EDM-cut, shaped from metal, shaped from wire, injection molded, or made by other suitable methods. The anchors can also be manufactured from other metals such as titanium.
[0051] The barbs of the skin anchors described above could optionally include a hollow portion and an exit hole or aperture adapted to be exposed to the undersurface of the skin once the barb penetrates the skin. A medicinal component, such as anesthesia (such as “Lidocaine”) or an anti-bacterial material, may be applied through the hole and thus to the skin. Any such medicinal component may be provided by a continuous source, such as by being connected to an IV drip, or be applied when the anchor is attached to the skin. In this manner, the medicinal component can be supplied around wound area 12 through skin punctures that have been created by the barbs of the skin anchors.
D. Tension Line
[0052] Referring back to FIG. 1 , tension line 130 of stretching element 120 is illustrated as being coupled to anchor 125 across wound 12 . Suitable examples for tension line 130 include nylon or polypropylene line, suture material, string, a cable, a wire, or other similar item. Line 130 should be sufficiently flexible and bendable to allow attachment to anchor 125 . In a preferred embodiment, tension line 130 is conventional suture material. One preferred line 130 is made from nylon and has a tensile strength of about 6 lbs to 10 lbs. Tension line 130 preferably includes a thread diameter of about 0.5 mm to 0.6 mm.
[0053] Although depicted as including a separate tensioning apparatus in FIGS. 1 and 2 , the stretching element 120 may instead utilize a line 130 that includes elastic material to provide the dynamic tension on skin anchors 125 . This elastic line may also be referred to as a biasing member that provides the tension needed to pull the anchors toward each other and the wound. With the use of a tensioning apparatus such as 140 , however, an inelastic line can be utilized to draw skin anchors 125 toward wound 12 since the tensioning apparatus is adapted to provide the dynamic force needed for wound closure. An elastic line can also be used in addition to a separate tensioning apparatus.
E. General Use of Wound Closure System
[0054] General assembly and use of the system will be described with reference to FIGS. 2 and 3 . In general use, first, the skin anchors 125 are placed at the opposing sides of a generally linear wound (see FIG. 1 for wound 12 ). After penetrating the skin by pressing the skin engagement barbs 122 of the anchors 125 into the skin, skin anchors 125 may then be further coupled to the skin with the use of, for example, staples 102 . The two pairs of indentations 126 defined on the body 124 of skin anchor 125 serve as target areas for placement of the staples 102 .
[0055] After one end of the tension line 130 has been secured to the spool 180 and the line wound around the spool, the tensioning mechanism 140 may be assembled with the spool 180 fitting into the base 160 . The free end of the line 130 is guided out of the snout portion 172 of the cover 170 . The biasing member 150 is placed on top of the spool 180 , and the cover 170 is mounted on top of the base 160 enclosing the tensioning apparatus 140 .
[0056] After assembly of the tensioning apparatus 140 , a loop is tied at the free end of the line 130 that is fed out of the snout portion 172 of the cover 170 . The loop is placed around the tension line tab 128 of the anchor 125 on one side of the wound. Then, the tensioning apparatus 140 may be pulled across the wound and attached to the anchor at the opposite side of the wound, with the biasing member 150 in a wound-up orientation. As anchors 125 move in toward each other and toward the wound by the stretching of the skin, the wound-up biasing member 150 and hence the spool 180 keeps line 130 taut. As mentioned above, depending on the size and shape of the wound, one or more stretching elements may be utilized as part of the wound closure system.
[0057] The tensioning apparatus 140 may be easily removed from the anchor 125 by holding the line 130 and pulling the tensioning apparatus back away from the anchor that it is attached to.
F. Alternative Embodiment of Wound Closure System
[0058] Referring to FIG. 7 , in an alternate configuration of a wound closure system 110 according to the present disclosure, skin anchors 225 (including features similar to anchors 125 of FIGS. 1 and 2 ) can be placed under the dermis 11 . In the configuration of the wound closure system 110 , the edges of a wound, such as wound 12 , would be undermined and then the skin anchors 225 would be inserted between the muscle layer 13 and the subcutaneous fat layer 15 . A line 230 from a tensioning apparatus 240 (line 230 and tensioning apparatus 240 including features similar to line 130 and tensioning apparatus 140 described above, respectively) would be attached to the skin anchors 225 . The tensioning apparatus may include a rigid conduit 261 through which line 230 may pass, the conduit 261 running from a snout portion 272 of a cover 270 of the tensioning apparatus 240 to the middle of the wound 12 . The rigid conduit 261 may be similar to a force guide tube disclosed in pending patent application Ser. No. 10/949,115 filed on Sep. 13, 2004, the disclosure of which is incorporated herein in its entirety. The rigid conduit 261 provides structural support for the line 230 and allows the tensioning apparatus 240 to be positioned at a remote location from the wound 12 . The rigid conduit provides a way to concentrate the pulling force of the tensioning apparatus 240 into a single point at the center of the wound 12 .
[0059] The sub-dermal skin anchors 225 may be made from any suitable material and may include features similar to skin anchors 125 . A preferred design is to have the skin anchor 225 made from stainless steel and having four skin engagement barbs 222 bent at an angle, such as 60 degrees.
[0060] In general use, to insert the skin anchors 225 , the physician would undermine the skin along the edge of the wound 12 . The subcutaneous fat layer 15 would be spread from the muscle layer 13 and the skin anchor 225 would be inserted therebetween. The skin engagement barbs 222 would then engage into the subcutaneous fat 15 and the dermis 11 . The skin engagement barbs 222 are preferably angled so that as more force is applied to the tension line 230 , the anchors 225 are pulled further into the dermis 11 .
[0061] In another embodiment of the skin anchors, the skin engagement barbs can be configured to pivot. The barbs could be configured such that the barbs would go from a flat position to an angled position via a pivoting structure such as a hinge. When first inserted into the skin, the skin engagement barbs would be flat or parallel to the surface of the skin anchors and as the anchors are pulled toward the wound by the tensioning apparatus 240 , the barbs would pivot up and start penetrating the subcutaneous fat layer 15 and the dermis 11 . An advantage of this design would be that it would not be necessary to spread the subcutaneous fat layer 15 from the muscle layer 13 as the skin anchors would be easy to slide in between the two layers. When tension is applied to the tensioner line 230 , the skin engagement barbs would pivot until a stop position is encountered. This stopping position could be provided at such a point that an angle of 60 degrees or a similar angle from parallel is achieved. The skin engagement barbs would then dig into the dermis and start stretching the skin as force is applied to the tension line 230 .
[0062] In another embodiment of the sub-dermal skin anchors, the skin anchors could be made from an absorbable material, that is, a material that is absorbed by body fluids.
[0063] Such a design has the advantage of not needing to remove the skin anchors after the skin has stretched adequately to close the wound. The anchors would just be left under the dermis and gradually dissolve.
[0064] It should be appreciated that the wound closure system 110 utilizing sub-dermal skin anchors 225 can be used with a linear wound closure system such as one described in the present disclosure or could be used with a radial wound closure system such as one described in the pending patent application Ser. No. 10/949,115 filed on Sep. 13, 2004. In a linear system, the line 230 coming out of the tensioning apparatus 240 would be split into two ends, each end being coupled to opposing skin anchors 225 to draw the skin anchors toward each other. In a radial system, a single line in the form of a loop can be coupled to anchors placed around the wound as described in further detail in pending application Ser. No. 10/949,115.
G. Alternative Use of Wound Closure System
[0065] The wound closure system may be used to stretch the skin for purposes other than for wound closure. One such example use of the wound closure system is directed to improving the cosmetic effects of male-pattern baldness. For example, the skin anchors may be placed on the human scalp such that the tension line extends across the so called “bald-spot.” The tensioning apparatus or an elastic tension line, for example, then, may be used to gradually draw the skin anchors toward each other to stretch the skin with the hair follicles surrounding the bald-spot to eventually reduce the size of the bald-spot.
[0066] From the foregoing detailed description, it will be evident that modifications and variations can be made in the devices of the invention without departing from the spirit or scope of the invention. Therefore, it is intended that all modifications and variations not departing from the spirit of the invention come within the scope of the claims and their equivalents. | A wound closure system and a method of closing a wound are disclosed. The disclosure is directed to a wound closure system comprising a skin anchor mechanically attached to external skin tissue on a first side of a generally linear wound, an anchorable tensioning apparatus mechanically attached to external skin tissue on an opposite side of the wound, and a line extending between the skin anchor and the tensioning apparatus to movably connect the anchor to the tensioning apparatus. The line is fixedly engaged with an anchor on one side of the wound while the tensioning apparatus provides tension on the line to draw the skin anchor and the tensioning apparatus toward each other and toward the wound. | 0 |
FIELD OF THE INVENTION
This invention relates in general to telephone hold circuits and more particularly to a hold release circuit employing a latching relay.
BACKGROUND OF THE INVENTION
In the course of receiving telephone calls, subscribers who have more than one local extension, frequently find it necessary to shunt (i.e. put to one side or hold in abeyance), a call received on the incoming line until a desired party is called to the telephone or is transferred from one to another local extension. The shunting of such a call is more commonly known as "holding" of a call. For this purpose telephone instruments are provided with a hold circuit activated by a "hold" key or a "hold" button. By manipulating this key or button a subscriber is able to transfer an incoming call to the holding circuit instead of to a local telephone instrument. This holding circuit is essentially a shunting circuit which simulates the electrical characteristics of the subscriber's local telephone instrument. This allows the handset of the telephone initiating the hold to be replaced "on-hook." The hold will be released when any of the extension telephones on the initiating telephone are taken "off-hook."
Although a hold and hold release circuit can be made with only solid-state devices, the complete solid-state circuit requires the use of high current SCR devices, high voltage transistors, and expensive varistors or other devices to protect the circuit from voltage surges. As a consequence, the solid-state circuits are costly and sometimes suffer from poor sensitivity, marginal operation on long loop conditions and an inability to detect high impedance extension phones going "off-hook." Finally, many hold and hold release circuits require a separate power source (not telephone line power) usually from the 110 VAC power line creating a possible hazardous condition.
SUMMARY OF THE INVENTION
The circuit of the present invention is totally telephone line powered and includes SCR control of storage capacitors for operation of a latching reed relay. The relay contacts are rated to withstand voltage surges and in the normally open state, protects the other components of the circuit. The hold release circuit will effectively sense various types of high or low DC resistance telephone extensions when going "off-hook," sensing a change in the telephone loop voltage level due to additional current drawn by the extension telephone.
When the hold is activated by momentary contact closure (user function button) an automatic timing function starts. If an extension telephone is picked up before the circuit times out, the hold will be released. If no extension or the master phone, goes "off-hook" within a specified time, (usually three to six minutes) the hold condition will automatically release.
The latching of the relay is controlled through a single coil by detecting current in opposite directions via first and second storage capacitors and a transistor for the "close" operation and a silicon controlled rectifier or SCR for the "open" operation. The transistor is controlled by an additional SCR which does not turn on until sufficient energy is stored in the first capacitor to trigger the SCR. The SCR used for opening the relay is turned on by either a sensing circuit or a time-out circuit through two diodes which isolate the two circuits from each other.
BRIEF DESCRIPTION OF THE DRAWING
The single sheet of drawings included herewith comprises a schematic diagram of the hold and hold release circuit embodying the principles of operation of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The included drawing schematically shows the hold and hold release circuit and elements well known and common to a telephone instrument. Line current is supplied to the hold and hold release circuit from the subscriber's line via the tip (T) and ring (R) leads and diode bridge network 10. The diode bridge 10 ensures that line current and voltage at the proper polarity irrespective of the polarity of the subscriber line is applied to the telephone transmission circuit (not shown) via leads 13 and 14 which are positive and negative, respectively, and to the hold circuit via leads 17 and 19 also positive and negative, respectively. A hookswitch contact 11 is included on lead 13 and is controlled by a typical hookswitch mechanism, which is manually operable into an operated or "off-hook" condition, i.e. when the handset is lifted off the telephone instrument, or non-operated, "on-hook" condition, i.e. when the handset is placed on the telephone instrument.
The hold circuit includes a relay latching circuit comprised of SCR 21 having its anode connected to pushbutton 15 and positive lead 13. The anode of SCR 21 is further connected through capacitor 41 to negative lead 19 of the hold circuit. The cathode of SCR 21 is connected to a latching reed relay coil 16 having a pair of diodes 22 and 23 connected on either end of the coil. A transistor 51 has its collector lead connected to the cathode of diode 23 and one end of coil 16 and its emitter connected to negative lead 19. The base lead of transistor 51 is connected to the cathode of diode 22 and the other end of coil 16 through a biasing resistor 32. Relay coil 16 controls a relay contact 12 located on positive lead 17 of the hold circuit. Contact 12 is arranged to open or close connecting or disconnecting, respectively the hold circuit from the line.
The hold release circuit includes a sensing device 61 comprised of a comparator or other like device having a positive input 64 connected to a voltage divider network comprised of resistors 34 and 35 and a voltage reference capacitor 45. The negative lead 66 of sensing device 61 is connected to a second voltage divider network comprised of resistors 36 and 37. The output 69 of sensing device 61 provides a trigger signal to the gate lead of SCR 24 through an isolation diode 25.
A second sensing device 62 comprised of a comparator or other like device has its output 68 also connected to SCR 24 through a second isolation diode 26. The positive lead 63 of sensing device 62 is connected to the voltage divider comprised of resistor 36 and 37. The negative lead 65 of sensing device 62 is connected to an RC network comprised of resistor 38 and capacitor 44. The hold circuit also includes a resistor 38 and LED 27 which provide a visual indication that the hold circuit is activated as well as shunting the majority of line current through the hold circuit.
A description of the operation of the hold and hold release circuit will hereinafter be described in detail. It should be noted that the included drawings show all contacts and switches in their unoperated conditions.
With a telephone instrument operated, hook-switch contact 11 makes connecting telephone line current from the tip (T) and ring (R) leads to the telephone transmission circuit via lead 13 and 14 and to the hold circuit via lead 17 and 19. Initially silicon controlled rectifier (SCR) 21 is in an off state as is relay 16. Contact 12 is open effectively disconnecting the hold circuit from the subscriber's line.
When the telephone subscriber wishes to place the call on hold, pushbutton 15 is momentarily depressed for a period until capacitor 41 charges sufficiently to provide the necessary gate trigger current for SCR 21. The voltage level to which capacitor 41 is charged to is controlled by telephone loop resistance, and resistor 31. Resistor 31 can be adjusted so that SCR 21 does not trigger until capacitor 41 has reached its practical maximum voltage. When capacitor 41 has charged sufficiently to provide trigger current for SCR 21, capacitor 41 discharges through SCR 21, diode 22, relay coil 16 and transistor 51 to the negative lead 19 of the hold circuit. Transistor 51 is turned on by a bias voltage through resistor 32 when SCR 21 turns on. The discharge current from capacitor 41 latches relay contact 12 closed connecting positive lead 17 to the hold circuit. After capacitor 41 completely discharges, SCR 21 and transistor 51 turn off, disconnecting the relay latching circuit. At this time, capacitors 42, 45 and 44 charge up through resistors 33, 34 and 38, respectively. LED 27 and current limiting resistor 39 carry the bulk of the line current and provides the load for seizing the subscriber's line. LED 27 turns on visually indicating that the hold function is operational. The master phone handset may now be placed "on-hook" disconnecting the transmission circuit from the subscriber's line.
The hold circuit is released in any of two ways. In the first method capacitor 44 and resistor 38 determine a time out period depending on the RC time constant of the circuit. The instant relay contact 12 closed, capacitor 44 charges to a negative potential through resistor 38 to a predetermined level. When capacitor 44 has charged for approximately one time constant sensing device 62 lead 65 becomes more negative than lead 63. Output lead 68 goes high coupling the signal through diode 26 to SCR 24. The output signal of device 62 is sufficient to trigger SCR 24 into forward conduction allowing the charge built up in capacitor 42 to dump through diode 23, relay coil 16 and SCR 24 to the negative side of the line 19. This unlatches the relay contact 12 disconnecting the hold circuit from the telephone line. The time-out period for the hold release circuit is dependent upon the values of capacitor 44 and resistor 38 and is normally between three to six minutes.
The hold circuit may be released before the time-out peiod by sensing if an extension telephone or the master phone is taken "off-hook." In this second method a second sensing device 61 has its output lead 69 connected to SCR 24 via an isolation diode 25. Sensing device 61 has a positive lead 64 connected to a voltage divider network comprised of resistors 34 and 35 which senses the loop voltage of the subscriber's line. A negative lead 66 is connected to a second voltage divider comprised of resistors 36 and 37 which sense drops in loop voltage within the subscriber's line such as when an extension phone goes "off-hook." Capacitor 43 provides a stable voltage reference for sensing device 61 and charges to the value of the loop voltage.
The hold circuit is activated in the manner discussed previously and the handset of the master telephone is placed "on-hook." If either an extension telephone or the transmission circuit of the master telephone is reconnected by taking the handset "off-hook," resistors 36 and 37 sense the drop in line voltage due to the decreased line current through the hold release circuit. The negative lead 66 of sensing device 61 becomes more negative in respect to the voltage sensed by lead 64 and referenced by capacitor 43. Sensing device 61 thereby outputs a high through lead 69, diode 25 to SCR 24 triggering SCR 24 into forward conduction. When SCR 24 turns on capacitor 42 dumps its charge through diode 23, relay coil 16 and SCR 24 to negative lead 19. This effectively unlatches contact 12 disconnecting the hold circuit from the subscriber's line.
The circuit is equally sensitive on short and long telephone loops with a wide range of extension telephone impedances. The relay contact effectively protects the circuit from any voltage surges which may be transmitted through the subscriber's line such as lightning surges and the like. The circuit does not respond to high voltage ring signals and does not drain ring current in the "off-mode."
Although the best mode contemplated for carrying out the present invention has been herein shown and described, it will be apparent that modifications and variations may be made without departing from what is regarded as subject matter of the invention. | In a hold circuit including a relay normally latched and connecting the hold circuit to a subscriber telephone line, a first hold release circuit outputs a trigger signal to a silicon controlled rectifier turning on the rectifier responsive to a sensed drop in line potential, thereby providing an electrical path for the discharge of a capacitor. The capacitor discharges through the coil of the relay unlatching the relay and releasing the hold circuit from the line. The hold circuit is also arranged to be released by a second hold release circuit which outputs a trigger signal to the silicon controlled rectifier responsive to a pre-arranged timing interval. | 7 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to barbecue ovens, and in particular to a barbecue oven having controlled heat and smoke flow.
BACKGROUND OF THE INVENTION
[0002] Barbecuing is a traditional cooking process that typically involves the cooking of foods by exposing them to relatively low temperature smoke for a number of hours. The structure used for barbecuing typically includes a heating or fire chamber, a cooking chamber and a conduit or flue through which smoke and heated combustion gases are transported from the fire chamber to the cooking chamber. Smoke and heat is produced by burning a smoke producing substance in the fire chamber such as wood. The wood is burned using a heating element such as a gas or electric burner. These burners are costly and it may be difficult to control the heat generated with the burners without additional devices such as sophisticated logic thermometers, dampers, vents and/or baffles. Accordingly, there exists a need for a barbecue oven that adequately controls the heat generated in the oven without using a burner and without the need for complex controllers or mechanical devices like dampers, vents or baffles.
SUMMARY OF THE INVENTION
[0003] In one aspect, an oven for cooking foods generally comprises a housing including a fire chamber and a cooking chamber disposed generally above the fire chamber. A vessel is receivable in the fire chamber and is adapted to hold combustible material therein to generate heat and smoke for cooking food in the cooking chamber. A blower is mounted on the housing. The blower is selectively operable to move air. A tube is attached to an outlet of the blower and extends into the fire chamber such that when the vessel is received in the fire chamber the tube extends to a position adjacent the vessel so that air from the blower is blown directly into the vessel without first passing a heating element.
[0004] In another aspect, an oven for cooking foods generally comprises a housing including a fire chamber and a cooking chamber disposed generally above the fire chamber. A vessel is receivable in the fire chamber and is adapted to hold combustible material therein to generate heat and smoke for cooking food in the cooking chamber. A blower is mounted on the housing. The blower is selectively operable to move air. A tube is attached to an outlet of the blower and extends into the fire chamber through an opening in the housing. The tube has an interior surface area and a generally square shaped cross section having an area. The ratio of the interior surface area to cross sectional area is at least about 20 to 1.
[0005] In yet another aspect, an oven for cooking food generally comprises a housing including a fire chamber having a volume and a cooking chamber disposed generally above the fire chamber. A vessel is receivable in the fire chamber and is adapted to hold combustible material therein to generate heat and smoke for cooking food in the cooking chamber. A blower is mounted on the housing. A tube is attached to an outlet of the blower and extends into the fire chamber through an opening in the housing. The blower is configured to blow air through the tube to produce a volumetric flow rate generally at an end of the tube in the fire chamber. The ratio of the volume of the fire chamber to the volumetric flow rate generally at the end of the tube is between about 1 to 1 and about 1 to 1.5.
[0006] In still another aspect, an oven for cooking food generally comprises a housing having a fire chamber and a cooking chamber disposed generally above the fire chamber. The fire chamber is configured to receive a vessel for holding combustible material therein to generate heat and smoke for cooking food in the cooking chamber. The oven further comprises a blower for blowing air into the fire chamber. The fire chamber is adapted to be substantially sealed from inflow of air surrounding the oven except from the blower.
[0007] In another aspect, a method of supplying heat to an oven in a controlled temperature range without the use of gas or electric burners generally comprises the steps of filling a vessel adapted for receipt in a fire chamber of the oven with charcoal. Placing the vessel in the fire chamber. Selectively blowing air into the filled vessel with a blower attached to the oven, the blower blowing air through a tube attached to an outlet of the blower and extending into the fire chamber to a position adjacent the vessel such that the air from the blower is blown directly into the vessel without first passing a heating element OR OTHER COMPONENT PART OF THE DEVICE. WE DON'T USE ANYTHING ELSE TO GET AIR IN THERE.
[0008] Other objects and features will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a left side perspective of a barbecue oven of the present invention with a door open to show internal construction;
[0010] FIG. 2 is a right side perspective of the barbecue oven with doors open to show internal construction;
[0011] FIG. 3 is a front elevation of the barbecue oven shown in FIG. 2 ;
[0012] FIG. 4 is a vertical section of the barbecue oven;
[0013] FIG. 5 is a perspective of a blower and tube of the barbecue oven;
[0014] FIG. 6 is a perspective of the barbecue oven as shown in FIG. 2 with a charcoal basket partially removed and supported by an ash tray;
[0015] FIG. 7 is an enlarged fragmentary perspective showing the charcoal basket and ash tray; and
[0016] FIG. 8 is a perspective of the charcoal basket filled with ignited and unignited charcoal.
[0017] Corresponding reference characters indicate corresponding parts throughout the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Referring now to the drawings and in particular to FIGS. 1-5 , a barbecue oven that efficiently circulates heat and smoke around food in the oven is designated generally by reference numeral 10 . For the purpose of illustration, the invention will be described in conjunction with a barbecue oven. The invention, however, should not be limited to this specific use, as it is instead intended that the invention be used in any application in which circulation of heated air around food is to be employed. The oven 10 includes a housing, indicated generally at 11 which comprises a front wall 12 , back wall 14 , side walls 16 , 18 , a top 20 and a bottom 22 . The front, back and side walls 12 , 14 , 16 , 18 define wall members which together form vertical walls of the housing 11 . The walls 12 , 14 , 16 , 18 , top 20 and bottom 22 are preferably seam welded together to form the housing 11 . The number of wall members forming the vertical wall may be other than described without departing from the scope of the present invention. The housing 11 is supported by legs 24 extending from the bottom 22 to position the oven 10 above an underlying floor F. Wheels 25 may be used to facilitate transport of the oven 10 . For the purposes of this description, the legs 24 , wheels 25 and any other supporting structure are considered part of the housing 11 . The housing is suitably constructed of heat resistant materials such as stainless steel. Other metals or porcelain coated materials suitable for use in cooking ovens can also be utilized. The oven 10 may include insulation material (not shown) in various parts of the oven to help maintain temperatures in the oven and to protect users from heat generated by burning fuel in the oven. Insulation may comprise a double-wall construction of the walls 12 , 14 , 16 , 18 , 20 , 22 of the housing 11 . The double-wall structure may also include insulating material between the walls such as high-temperature mineral wool or other non-combustible materials.
[0019] A heat flow regulating fire wall 26 divides the interior of the oven 10 into a fire chamber 28 and a cooking chamber 30 . In one embodiment, the firewall 26 extends between the opposite side walls 16 , 18 along a width W of the oven 10 ( FIG. 3 ) and extends from the front wall 12 to near the back wall 14 along a depth D of the oven ( FIG. 4 ). The fire chamber 28 has an approximate length L fc of about 2 ft., an approximate height H fc of about 1.08 ft., and an approximate width W fc of about 1.58 ft. Therefore, the fire chamber 28 has an approximate volume of about 3.4 cubic feet. An angled plate 29 is welded to the bottom 22 and back wall 14 . The fire chamber 28 is in the lower part of the oven beneath the firewall 26 , and the cooking chamber 30 is above the firewall. Thus, the oven 10 has a generally vertical orientation, with the cooking chamber 30 located above the fire chamber 28 . The firewall 26 has a generally arcuate shape with a back portion 33 that extends upward to form a tapered duct 32 having a throat, or outlet 34 between the firewall and the back wall 14 . The duct 32 is defined by the back portion 33 of the firewall 26 , a portion of the back wall 14 generally opposing the back portion and sections of the side walls 16 , 18 extending between the back portion and opposing portions of the back wall. It is believed that heated air and smoke from the fire chamber 28 is provided with an upward thrust by the angled plate 29 and passes through the throat 34 to the cooking chamber 30 , as will be more fully explained below. The shape of the firewall 26 may be described as a segment of an ellipse ( FIG. 4 ). One or more flanges (not shown) extending from the firewall 26 to the back wall 14 may be used to secure the firewall to the back wall without substantially blocking the throat 34 . The firewall 26 is fixed to the front wall 12 and the side walls 16 , 18 of the housing 11 by welding. However, the firewall 26 can be fixed to the housing 11 using suitable brackets and fasteners (not shown) without departing from the scope of the invention. Continuous seam welds are preferred, at least in the region of the fire chamber 28 . For ovens such as the oven 10 described in the present invention, a firewall like firewall 26 is preferred for controlling heat flow in the oven.
[0020] A food rack, indicated generally at 40 , is located within the cooking chamber 30 . As shown, the food rack 40 includes a series of slidable horizontal shelves 42 supported on brackets 44 that are secured to the side walls 16 , 18 of the housing 11 . Each bracket 44 includes vertically spaced rails 46 , each aligned with a corresponding one of the rails 46 on the bracket 44 on the opposite side wall 16 or 18 . The rails 46 of each pair of aligned rails receive opposite edge margins of one of the racks 42 to support the rack in the cooking chamber 30 . Generally speaking, the food rack 40 may have various configurations including rotating slits, rotisserie wheels, baskets or even stationary shelves without departing from the scope of the invention.
[0021] A lid or door 50 A makes up a portion of the front wall 12 and the top 20 of the housing 11 and provides access to the cooking chamber 30 . The door 50 A may have a heat resistant glass window (not shown) located therein to allow the user to monitor the food product being cooked without having to open the door. A thermometer 52 may be mounted on side wall 18 adjacent the door 50 A to indicate the temperature inside the cooking chamber 30 of oven 10 to monitor the heat produced in the fire chamber 28 as will be explained in greater detail below. It will be understood that the thermometer 52 may have other locations on the oven 10 without departing from the scope of the present invention. During operation of the oven 10 , the door 50 A is typically closed except when inserting food or retrieving food from the oven.
[0022] In one embodiment, the firewall 26 is shaped with a front edge 54 , back edge 56 and middle portion 58 ( FIG. 4 ). The back edge 56 is located vertically higher in the oven 10 than the middle portion 58 such that the firewall 26 has a concave shape opening upward toward the cooking chamber 30 . The position of the firewall 26 below the food rack 40 permits the firewall to act as a drip pan for catching grease and other meat drippings produced by food while it is cooking on the racks 40 . It will be understood that the firewall may have other configurations within the scope of the present invention.
[0023] The heated air and smoke in the cooking chamber 30 circulate in a generally circular or elliptical path around the food products on the food rack 40 , flowing up the rear wall 14 , across the top 20 of the cooking chamber, down the front wall 12 , and over the fire wall 26 . The accelerated current of heated air and smoke passing through the throat 34 of the tapered duct 32 entrains the air in the cooking chamber 30 to provide momentum and to keep the air circulating in this circular pattern. The accelerated heated air stream flowing through the tapered duct 32 reduces heat stratification in the cooking chamber 30 , even when there is no artificial means to circulate the air within the cooking chamber. Thus, this circulation path within the oven 10 is configured to eliminate the need for baffles, flues or convection fan blades (not shown) located in the cooking chamber 30 for distributing the heated air around the food products being cooked. The shape of the duct 32 and cooking chamber 30 may have other configurations without departing from the scope of the present invention. Moreover, baffles, flues and or convection fan blades may be used with the present invention although less desirable.
[0024] In one embodiment, smoke exits the cooking chamber 30 through one or more portals 64 located in the sidewalls 16 , 18 of the housing. The portals 64 (only one illustrated in FIG. 4 ) serve as openings into exhaust ducts 66 contained within the sidewalls 16 , 18 . Desirably, the portals 64 are located in the sidewalls 16 , 18 so that the portals are below the bottom-most portion of the food rack 40 . This location of the portals 64 facilitates removal of smoke in an amount and rate which promotes circulation of smoke and maintenance of smoldering solid fuel in the fire chamber 28 . Thus, food in the oven is properly flavored by the smoke without being over-exposed to the smoke. The exhaust ducts 66 desirably have a bottom surface that slopes upward from the interior surface of the sidewall to the outward surface of the exhaust duct so that any grease splattering into the portals 64 is discouraged from accumulating in the ducts. The exhaust ducts 66 are suitably about 4 inches wide and about ¾ of an inch deep and form a conduit leading to exhaust stacks 68 near the top 20 of the oven 10 which can be open to the atmosphere or connected to a suitable chimney. The exhaust stacks 68 extend from the housing 11 above the sidewalls 16 , 18 so as to not interfere with the door 50 A. Ambient heat in the cooking chamber 30 is transferred through the side wall 16 , 18 to the confined space in the exhaust duct 66 to aid in transporting the smoke. When heated, the exhaust ducts 66 transport heat and smoke through the exhaust stacks 68 to the atmosphere, promoting the circulation of the smoke and heat within the cooking chamber 30 . Other means for venting smoke from the cooking chamber 30 are contemplated without departing from the scope of the invention.
[0025] The fire chamber 28 contains a charcoal basket (broadly, “a solid fuel vessel”) generally indicated at 70 . The charcoal basket 70 holds combustible material such as charcoal or charcoal bricks and other fuels besides charcoal. The charcoal basket 70 may also contain a relatively small quantity of smoke producing material such as wood chips, wood chucks or pellets (not shown). Referring to FIGS. 6 and 7 , the charcoal basket 70 includes downwardly extending end walls 72 and downwardly extending mesh side walls 74 that lead to a substantially planar bottom wall 75 ( FIG. 4 ). As best seen in FIG. 8 , the charcoal basket 70 is suitably elongated in shape and spans nearly the entire width W of the oven 10 . As illustrated, the charcoal basket has a length L b of about 19 in., a height H b of about 7 in. and a width W b of about 6 in. Thus, the illustrated charcoal basket 70 has a height to width ratio of about 1.2. In one embodiment, the charcoal basket 70 has a ratio of height H b to width W b of at least about 1. An upper flange 79 extends outwardly around the top of the charcoal basket 70 . The charcoal basket 70 is accessible and removable through a side door 77 . The door 77 is provided with a gasket 80 to seal the fire chamber 28 when the door is closed. In the illustrated embodiment, the charcoal basket 70 is partially formed from expanded metal. However, other suitable configurations of the charcoal basket 70 are within the scope of the invention.
[0026] Beneath the bottom 22 of the oven 10 , below the charcoal basket 70 , is a removable ash tray 76 for collecting expended ash material. The ash tray 76 includes a substantially horizontal planar member 78 . The ash tray 76 is mounted below side wall 16 and suitably removable from below the oven 10 for convenient emptying of the ash. The ash tray 76 can also be partially removed ( FIG. 6 ) to serve as a support for the charcoal basket 70 when loading the charcoal into the charcoal basket as will be explained in greater detail below. In another embodiment (not shown), an ash tray could be formed integral with the bottom of an oven and slidable out from a fire chamber conjointly with a charcoal basket carried by the ash tray.
[0027] A blower 84 is located in a forward compartment 86 behind the front wall 12 of the housing 11 adjacent the fire chamber 28 . The compartment 86 comprises a top wall 88 and side wall 89 . A door 50 B closes off the compartment 86 to the surrounding environment. However, vents 85 allow the blower 84 to draw in air from the surrounding environment for operation. The blower 84 is mounted in the compartment 86 in a suitable manner such as by a bracket 96 . A square tube 94 is attached to an outlet of the blower 84 by a flange 98 and extends through an opening in side wall 89 and into the fire chamber 28 . The tube 94 has a length L t of about 16 in., an inside perimeter P t of about 3 in., and a uniform cross-sectional area CA of about 0.56 in 2 ( FIG. 5 ). Thus, the tube 94 has an internal surface area of about 48 in 2 . Therefore, the ratio of the internal surface area to the cross-sectional area of the tube 94 is about 85 to 1. In one embodiment, the ratio is at least about 20 to 1. In another embodiment, the ratio is at least about 50 to 1. The tube 94 extends about 7½ in. into the fire chamber 28 to a position about 1 to about 5 in. (2.5 to 12.7 cm.) from the charcoal basket 70 . Therefore, the tube 94 extends into the fire chamber 28 a distance greater than a greatest cross sectional dimension of the tube. In the illustrated embodiment, the charcoal basket is not located in the fire chamber 28 by any specific structure. However, it is envisioned that a locating element (not shown) could be use to precisely position the charcoal basket 70 in the fire chamber 28 with respect to the end of the tube 94 . Also, multiple tubes and/or multiple blowers (not shown) can be used to accommodate larger ovens requiring larger charcoal baskets. For example, a single blower could exhaust into a manifold from which several tubes extend into the fire chamber.
[0028] The blower 84 has a motor 90 which directs air though the tube 94 directly into the charcoal basket 70 . The tube 94 directs the air from the blower 84 to a position about mid-height and mid-length of the charcoal basket 70 and generally perpendicular to the side walls 72 of the charcoal basket. The tube 94 is free of any dampers, vents, baffles or any other devices for regulating air flow. Also, there are no heating elements disposed between the end of the tube 94 and the charcoal basket 70 . In fact, there are no heating elements within the fire chamber 28 . The blower motor 90 can be an electric motor capable of operating at various speeds. However, in the illustrated embodiment, the blower motor 90 operates at a single speed generating an air flow rate of about 1600 FPM. The length L t and cross-sectional area of the tube 94 produce an air flow rate generally at the end of the tube between about 820 to about 850 FPM (about 3.2 to about 3.3 cubic feet/min). Thus, the ratio of the approximate volume of the fire chamber 28 and the volumetric flow rate generally at the end of the tube 94 is between about 1 to 1 and about 1 to 1.5.
[0029] In the illustrated embodiment, a thermostat 100 , broadly a controller, is mounted on the housing 11 and is connected to the blower motor 90 by electrical wiring and controls in a conventional manner. The thermostat 100 is adjusted to maintain a desired temperature within the cooking chamber 30 by switching the blower 84 on and off. As shown in FIG. 1 , thermocouples 102 , broadly temperature sensors, are mounted in the cooking chamber 30 of the housing 11 and provide temperature input to the thermostat 100 . The thermocouples are secured to a mount 144 . The thermocouples 102 may be secured within the cooking chamber 30 at other locations within the scope of the present invention. Further, a protective screen 146 covers and protects thermocouple tubes and connectors (not shown) while also allowing the ambient air of the cooking chamber 30 to flow around the tubes and connectors for more accurate measurements.
[0030] The thermostat 100 may be a conventional thermostat such as a Robertshaw 5300-17E and may use simple logic or may receive input from additional thermocouples (not shown) and use staged or sequenced logic. However, in one embodiment only simple logic is used. When the desired temperature is achieved, (suitably between about 150 degrees F. and about 250 degrees F., the thermostat 100 automatically turns off the blower 84 . When the temperature in the cooking chamber 30 falls sufficiently below the desired temperature, such as to a range between about 5 degrees F. and about 10 degrees F., the thermostat 100 turns the blower 84 on, thus reestablishing combustion in the solid fuel and restoring the cooking chamber 30 to the desired temperature. In this manner, the thermostat 100 controls the blower 84 to restore combustion of the fuel and maintain the air temperature within the oven 10 within a predetermined range. One of the reasons a simple logic thermostat is used is because it is easy calibrate. More complex thermostats may require a trained professional to perform the calibration. Also, the electronics associated with complex thermostats are susceptible to damage when they experience elevated temperatures such as those required for cooking food in an oven. The thermostat 100 of the present invention needs only a small set screw (not shown) for calibration. However, it is understood that a thermostat having complex functions could be used in the present invention. The complex functions, however, are not necessary to maintain temperature control. One example of a feature that could be present in both a simple or complex logic thermostat is a cook and hold feature where the thermostat is programmed to drop the temperature in the cooking chamber 30 after a certain period of time (e.g., at end of cooking cycle). This feature keeps the cooked food warm without further cooking (e.g., 225 F to 150 F).
[0031] In use, the charcoal basket 70 can be partially removed from the fire chamber 28 and supported on the ash tray 76 to provide access to the charcoal basket ( FIG. 6 ). The charcoal basket 70 can also be completely removed from the fire chamber 28 and supported by the floor F. The charcoal basket 70 is then filled half way with ignited charcoal. The remaining portion of the charcoal basket 70 is filled with unignited charcoal such that the top half of the charcoal basket is occupied by the unignited charcoal. The charcoal basket 70 is then placed in the fire chamber 28 and the door 77 is closed to seal off the fire chamber. It is understood that the charcoal could also be loaded into the charcoal basket 70 while the charcoal basket is completely housed in the fire chamber 28 . Other proportions of ignited and unignited charcoal could be used, including using all ignited charcoal.
[0032] The thermostat 100 can then be set to a desired temperature for cooking food in the cooking chamber 30 . In a preferred embodiment, the thermostat 100 is set to a temperature between about 150 and about 250 degrees F. The sensor 102 in the cooking chamber 30 then senses the temperature in the cooking chamber. If the temperature is below the desired temperature, the thermostat 100 will turn on the blower 84 so that the blower blows air through the tube 94 and onto the charcoal in the charcoal basket 70 . A combustion reaction is produced when the oxygen in the air energizes the ignited charcoal releasing smoke and heat which cause the temperature in the fire chamber 28 to rise, thus causing the temperature in the cooking chamber 30 to rise. The blower 84 will remain on, producing a sufficient air flow to energize the ignited charcoal and increase the temperature in the cooking chamber 30 until the desired temperature is reached. When the desired temperature is reached the thermostat 100 automatically turns the blower 84 off. For purposes of this description, this type of thermostat is considered to be an “on/off control.” Once the desired temperature in the cooking chamber 30 is reached, the oven 10 is configured to maintain this temperature for an extended period of time. In addition to the configuration of the tube 94 and blower 84 which will be explained below, the housing 11 and firewall 26 of the oven 10 are sized and shaped to help maintain the cooking chamber 30 at the desired cooking temperature. The tapered duct 32 formed by the fire wall 26 and the rear wall 14 of the housing create a choke that prevents a large influx of air and heat leaving the fire chamber 28 , limiting the draw into the fire chamber through back pressure. Inhibiting the charcoal in the fire chamber 28 from overfiring allows the heat in the cooking chamber to be maintained at a steady temperature for extended periods of time. Also, the size and location of the portals 64 leading to exhaust ducts at the bottom of the cooking chamber 30 help to control the flow of air in the cooking chamber. Smoke is exhausted in an amount and at a rate which promotes circulation of the smoke in the cooking chamber and maintenance of the fuel in the fire chamber 28 . This provides additional control over the temperature in the cooking chamber 30 .
[0033] However, with the blower 84 off, the source of oxygen to the fuel (charcoal) is substantially removed; therefore the temperature in the fire chamber 28 will eventually begin to gradually decrease causing the temperature in the cooking chamber 30 to decrease. Once the temperature in the cooking chamber 30 decreases by an amount of about 5 to about 10 degrees F., the thermostat 100 will automatically turn the blower 84 back on, blowing air into the charcoal basket 70 to reenergize the ignited charcoal to again raise the temperature in the fire chamber 28 so that the temperature in the cooking chamber also raises, back to the desired cooking temperature. Once the desired cooking temperature is reached again, the thermostat 100 automatically turns the blower 84 back off. It will be understood that over time the energized ignited charcoal will burn such that it will light the unignited charcoal above the ignited charcoal, replenishing the fuel source to maintain the cooking chamber 30 at the desired temperature for cooking the food. Moreover, adding additional unlit charcoal to the basket 70 facilitates the continued combustion reaction aiding in the maintenance of the desired cooking temperature in the cooking chamber 30 .
[0034] The size and length of the tube 94 , and the range of about 820 to about 850 FPM for the flow rate of the air at the end of the tube are selected because they provide a rapid elevation of the temperature in the oven 10 without “over firing” the charcoal. Over firing is a condition that occurs when too much oxygen is supplied to the charcoal to the point where the combustion reaction continues of its own accord, creating its own draw to supply additional oxygen. The charcoal will continue to ignite even after the blower has been tuned off. This will result in a spike in the temperature above the desired cooking temperature. This is not ideal when cooking foods at low and slow temperatures, such as when smoking foods. Further, the oven 10 is configured such that the reintroduction of charcoal to the fire chamber 28 can be performed while the oven is in operation without running the risk of over firing the charcoal and spiking the temperature in the cooking chamber 30 . Even with the fire chamber door 77 open, the tapered duct 32 and the location of the portals 64 help control the temperature in the cooking chamber 30 .
[0035] In addition to the size and length of the tube 94 , and the flow rate generated in the tube, the tube directs air to a location that is about mid-height and mid-length of the charcoal basket 70 so that the charcoal in the charcoal basket is evenly energized and ignited. Also, the square shape of the tube 94 is believed to produce a turbulent flow of air causing the air to disperse or spread along the charcoal basket 70 . This dispersion of air is not as easily produced with a round tube which generates substantially laminar flow. Thus, the location to which the tube 94 directs air into the charcoal basket 70 along with the shape of the tube further reduce the chance of over firing the charcoal.
[0036] Generally speaking, the use of the ignited charcoal to begin the process eliminates the need for any heating elements such as gas or electric burners to provide the heat source necessary to create the combustion cycle described above. The pre-ignited charcoal also reduces the initial heating time needed to reach the desired cooking temperature. The charcoal itself is preferred because the uniform pieces provide a stable and predictable temperature change within the fire chamber 28 . Additional solid fuel sources such as woodchips, wood chucks or pellets may be used to produce added smoke and to flavor the food being cooked.
[0037] Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
[0038] When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
[0039] In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
[0040] As various changes could be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | An oven for cooking foods includes a housing having a fire chamber and a cooking chamber disposed generally above the fire chamber. A vessel is receivable in the fire chamber and is adapted to hold combustible material therein to generate heat and smoke for cooking food in the cooking chamber. A blower is mounted on the housing. The blower is selectively operable to move air. A tube is attached to an outlet of the blower and extends into the fire chamber such that when the vessel is received in the fire chamber the tube extends to a position adjacent the vessel so that air from the blower is blown directly into the vessel without first passing a heating element. The oven does not require supplemental heat from a burner or similar heating element. | 8 |
FIELD OF THE INVENTION
This application is a continuation-in-part of application Ser. No. 763,406, filed on Jan. 28, 1977 U.S. Pat. No. 4,153,574.
This invention relates to compositions containing a dispersed form of a trialkyltin fluoride. More particularly, this invention relates to stable dispersions of trialkyltin fluorides which are capable of being stored for extended periods of time without any significant increase in viscosity.
A number of trialkyltin fluorides, particularly tri-n-butyltin fluoride, effectively inhibit the attachment and growth of barnacles and other organisms responsible for fouling of submerged surfaces such as the hulls of sea-going vessels and the pilings of docks and other facilities exposed to salt water. The trialkyltin fluorides are, therefore, useful as the toxicant for antifouling coatings. A typical antifouling coating contains the toxicant, one or more pigments and a film-forming polymer. All of these components are dissolved or dispersed in an organic solvent such as xylene or toluene, optionally in combination with a ketone such as 2-butanone.
Up until now, acceptable coatings containing trialkyltin fluorides, which are solid materials at ambient temperatures, have been difficult to prepare. Dispersions of trialkyltin fluorides in organic solvents exhibit a strong tendency to agglomerate in the form of large particles. These materials therefore cannot be dispersed in coating compositions or organic solvents by mixing at high speeds. This unusual behavior can be explained in terms of a difference between the electronegativities of tin and fluoride. This difference results in a relatively weak attractive force between the tin atom on one molecule and the fluoride atom on an adjacent molecule, resulting in a structure resembling that of a linear polymer molecule. Regardless of the cause, the agglomeration is undesirable, since it makes it difficult or impossible to prepare a useful coating formulation wherein the maximum particle size is 45 microns or less. This degree of fineness cannot be achieved without grinding the formulation in a pebble mill or a ball mill, a tedious, time-consuming operation. Even following such a grinding procedure, there may still be a number of hard agglomerates present in the formulation. These agglomerates must be removed manually to obtain a useful coating composition.
It is, therefore, an objective of this invention to obtain stable dispersions of trialkyltin fluorides which can be readily dispersed in coating compositions without the need for grinding to achieve the desired particle size.
Surprisingly, it has now been found that the presence of certain inorganic compounds enable trialkyltin fluorides such as tri-n-butyltin fluoride to be dispersed in a specified class of organic solvents without agglomeration to yield stable compositions. The resultant compositions remain stable for extended periods of time and can readily be incorporated into coating compositions, including paints.
Japanese Patent Publication No. 7338847 discloses heating tri-n-butyltin fluoride at 40° to 60° C. in a liquid hydrocarbon or halogenated hydrocarbon that boils from 50° to 200° C. The resultant slurry hardens upon standing for any appreciable length of time, and hence is not practical for incorporation into antifouling coatings. Even after being ground the resultant particles do not yield a dispersion of adequate "fineness".
SUMMARY OF THE INVENTION
This invention provides a stable, thixotropic dispersion of a trialkyltin fluoride, said dispersion consisting essentially of:
(1) from 40 to 70% by weight of a trialkyltin fluoride of the formula R 3 SnF, wherein R is alkyl containing from 2 to 12 carbon atoms;
(2) from 20 to 60% by weight of at least one organic liquid having a kauri butanol value of 96 or less and selected from the group consisting of alcohols containing from 4 to 12 carbon atoms, aliphatic hydrocarbons containing from 5 to 12 carbon atoms, aromatic hydrocarbons;
(3) from 0.5 to 10% by weight of a compound selected from the group consisting of:
(a) lithium and sodium salts of p-toluenesulfonic, phenylphosphonic and silicic acids;
(b) nitric acid salts of calcium, magnesium, sodium, lithium, iron and zinc;
(c) salts of p-toluenesulfonic or phenylphosphonic acid and an element selected from the group consisting of magnesium, calcium, strontium and barium;
(d) the chlorides of metallic elements selected from the group consisting of divalent copper, silver, gold and the elements in Groups II-A, II-B, IV-A, IV-B, V-A, VI-B, VII-B and VIII of the periodic table, and
(e) carboxylic acid salts of lead, manganese, zirconium, barium and strontium, wherein said carboxylic acid contains from 2 to 12 carbon atoms.
DETAILED DESCRIPTION OF THE INVENTION
The novel feature of the present trialkyltin fluoride compositions resides in the presence, in relatively small amounts, of compounds derived from one of the metallic elements. These compounds stabilize the dispersion by preventing agglomeration of the trialkyltin fluoride particles. The accompanying examples demonstrate that many members of this class of compounds are not suitable stabilizers, and it is therefore difficult to predict without experimentation which compounds are operable. For example, while sodium compounds are generally useful, the only effective potassium compound is the hydroxide. The liquid medium is also a critical factor with respect to stability of the dispersion.
The cationic portion of those compounds found to be effective dispersion stabilizers is derived from one of a number of specified metallic elements, and includes members from groups I-A, I-B, II-A, II-B, IV-A, IV-B, V-A, VI-B, VII-B and VIII of the periodic table. The anionic portion of the molecule is a residue of an inorganic acid such as nitric or silicic acid, or an organic acid such as p-toluenesulfonic acid, phenylphosphonic acid or a carboxylic acid containing from 2 to 12 carbon atoms. Representative carboxylic acids include acetic, propionic, butyric, hexoic, heptanoic, cyclohexanecarboxylic and benzoic acids.
Chlorides of polyvalent metallic elements are also effective dispersion stabilizers. By comparison, a dispersion containing sodium chloride solidifies upon standing. With the exception of potassium hydroxide, this is also true for dispersions containing the potassium analogs of the sodium compounds disclosed in this application and in copending application Ser. No. 763,406, of which the present application is a continuation-in-part.
In addition to choice of the proper inorganic dispersion stabilizer, the organic liquid used as a dispersion vehicle is also critical to obtaining a non-coagulating dispersion of a trialkyltin fluoride. Suitable organic liquids include aliphatic hydrocarbons and aromatic hydrocarbons having a kauri butanol value of 96 or less. The kauri butanol value of a hydrocarbon solvent is equal to the volume in cubic centimeters (measured to 25° C.) of a given solvent that will produce a specified degree of turbidity when added to 20 g of a standard solution of kauri resin in normal butanol. The test method is published by the American Society for Testing and Materials as ASTM Test No. 01133-61 (reapproved in 1973). The pertinent portions of this testing procedure are hereby incorporated by reference.
Representative useful liquid hydrocarbons include the aliphatic hydrocarbons. These hydrocarbons can be used individually or in mixtures that are commercially available as mineral spirits, petroleum ether and naphtha. The class of aromatic hydrocarbons includes xylene. Toluene has a kauri butanol value of 105, and is therefore not a suitable medium for the present dispersions, however, it can be used in mixtures with aliphatic hydrocarbons. Other useful liquid media include alcohols containing 1, 2 or 4 carbon atoms, such as methanol, ethanol and butanol. Surprisingly, a stable dispersion cannot be prepared in n-propanol.
The trialkyltin fluorides that can be employed in the stable dispersions of this invention are of the general formula R 3 SnF, wherein R is alkyl and contains from 3 to 6 carbon atoms. If the dispersion is to be incorporated into a coating material intended to inhibit fouling by barnacles and other organisms on ship hulls and other normally submerged structures, R is preferably n-butyl.
Using the dispersion stabilizers and organic liquids disclosed in the preceding specification and accompanying claims, it is possible to prepare compsitions containing from about 10% up to about 70% by weight of a trialkyltin fluoride. It has heretofore not been possible to incorporate more than about 40% by weight of a trialkyltin fluoride such as tri-n-butyltin fluoride in a dispersion. The maximum amount of fluoride that can be dispersed will, of course, be dependent upon the particular dispersion stabilizer and organic liquid selected.
The physical forms of the present dispersions vary from viscous liquids to semi-solid pastes, depending upon the concentration of the trialkyltin fluoride. One important advantage of these compositions is that they exhibit thixotropy, and can therefore be easily blended by stirring the composition together with other ingredients conventionally used in paints and other coating compositions. These additional ingredients include natural or synthetic film-forming polymers such as rosin and copolymers of vinyl chloride with one or more ethylenically unsaturated monomers such as vinyl acetate, pigments such as titanium dioxide and iron oxide, viscosity modifiers, particularly clays such as bentonite, and one or more organic solvents.
Typical antifouling coatings that can be prepared using the present dispersed form of trialkyltin fluoride contain from 1.0 to 20.0 of the trialkyltin flouride composition, including one or more of the aforementioned salts and organic liquids, from 10 to 50% by weight of pigments, typically titanium oxide or zinc oxide alone or in combination with colored pigments such as ferric oxide, from 10 to 50% by weight of at least one film-forming component, which typically includes vinyl chloride homopolymers and copolymers, rosin and chlorinated rubbers such as polychloroprene, and from 20 to 60% by weight of one or more organic solvents, including xylene, cyclohexanone, 2-butanone and mixtures of hydrocarbons commonly referred to as "aliphatic naphtha" and "high flash naphtha". A small amount of a viscosity modifier such as a bentonite clay is usually included to impart thixotropy to the final coating composition.
The preparation of a particularly preferred coating formulation is described in one of the accompanying examples.
Incorporating tri-n-butyltin fluoride into a paint formulation has heretofore been a lengthy, time-consuming procedure due to the tendency of the flouride to agglomerate. The resultant paint usually must be ground for several hours in a pebble or sand mill to obtain a fineness of 4 to 5 on the Hegman N.S. Scale of 0 (no grind) to 10 (excellent grind). A rating of 4 to 5 on this scale is equivalent to an average particle size of from 40 to 70 microns. Similar problems resulting from agglomeration are encountered if an attempt is made to disperse the trialkyltin flouride in an organic solvent prior to incorporating it into a paint formulation. In addition, once a dispersion of the desired particle size is obtained, it cannot be stored for any length of time, since it rapidly hardens to a waxy solid.
The accompanying examples disclose preferred embodiments of the present compositions and should not be interpretted as limiting the scope of the accompanying claims. In the examples all parts and percentages are by weight unless otherwise indicated.
EXAMPLE 1
Dispersions of tri-n-butyltin flouride were prepared by blending 60 parts of this compound, 5 parts of the inorganic stabilizer and 35 parts of a mixture containing 64% special naphthalite (a mixture of liquid hydrocarbons containing less than 8% of aromatic hydrocarbons), 12% ethyl benzene, 9% n-butyl acetate, 5% iso-butyl acetate and 10% n-butanol. The flash point of the mixture is 14.4° C., the kauri butanol number is 36 and the boiling range is from 123° to 145° C. One hundred grams of the resultant mixture were placed in a cylindrical container measuring two inches (5.1 cm) in diameter and 4.5 inches (11.4 cm) in height. Into the same container were also placed 250 grams of stainless steel spheres measuring 4.7 millimeters in diameter. The container was then sealed and shaken vigorously for twenty minutes, after which the contents of the container were emptied onto a large mesh wire screen. Dispersions which solidified during milling and crumbled when prodded with a spatula were considered unacceptable and were not tested further. Acceptable materials were either viscous liquids or homogeneous, coherent semi-solids which could be forced through the openings of the screen using a spatula. Those materials which passed through the screen were collected and maintained under ambient conditions for two days. At the end of the period, they were examined to determine whether any changes in their physical form had occurred during this interval. Those materials which had solidified and could no longer be stirred with a spatula were considered unacceptable. All of the acceptable materials were thixotropic semi-solids or viscous liquids that exhibited a significant viscosity reduction under shear. Some of the materials appeared to be coherent solids yet could readily be stirred by hand with a spatula using only a minimal amount of force.
Inorganic compounds yielding acceptable dispersions included:
Sodium p-toluenesulfonate
Calcium di-(p-toluenesulfonate)
Sodium Phenylphosphonate
Calcium Phenylphosphonate
Barium Acetate
Strontium Acetate
Zirconium Acetate
Manganous Acetate
Lead Acetate
Calcium Nitrate
Ferrous Nitrate
Ferric Nitrate
Zinc Nitrate
Sodium Silicate
Magnesium Chloride
Calcium Chloride
Manganous Chloride
Ferrous Chloride
Ferric Chloride
Cupric Chloride
Stannous Chloride
Bismuth Chloride
Compounds which did not yield acceptable dispersions included:
Potassium p-toluenesulfonate
Potassium Phenylphosphonate
Potassium Acetate
Nickel(ous) Acetate
Cuprous Acetate
Cupric Acetate
Cadmium Acetate
Potassium Nitrate
Barium Nitrate
Nickel(ous) Nitrate
Magnesium Silicate
The chlorides of sodium, potassium & monovalent Copper
Calcium Fluoride
It is believed that an effective stabilizer will interfere with the formation of strong bonds between the fluorine atoms on one molecule and tin atoms on adjacent molecules. This bond formation is believed responsible for the agglomeration which almost always occurs when a trialkyltin fluoride is dispersed into an organic solvent in the absence of one of the present inorganic compounds.
EXAMPLE 2
The effect of vaarious organic liquids or diluents on the stability of a dispersion containing 60% by weight of tri-n-butyltin fluoride, 5% of calcium carbonate and 35% of the organic liquid was determined by preparing a dispersion as described in the preceding example. Those dispersions which could be classified as viscous liquids or coherent semi-solids following the initial milling operation were stored for one week under ambient conditions and then examined to determine whether the original thixotropic character had been retained.
The organic liquids evaluated included a mixture of aromatic hydrocarbons available as Solvesso® 150 from the Exxon Company and typically having a flash point from 145° to 150° F. (63° to 65° C.), VM&P naphtha [a mixture of aliphatic hydrocarbons typically having a flash point of 6.7° C. (tag closed cup) and a boiling range from 118° to 139° C.]; mineral spirits [a mixture of aliphatic hydrocarbons typically having a flash point of 42.2° C. (tag closed cup) and a boiling range from 160° to 196° C.]; ethyl benzene, amyl acetate, a mixture (A) containing 33.3% of VM&P naptha, 28.9% cyclohexane and 37.8% amyl acetate and a second mixture (B) containing 34.2% mineral spirits, 4.4% Solvesso® 150, 12.2% ethyl benzene and 49.2% amyl acetate.
Also included in the evaluation were cyclohexane, xylene, 2-butanone, n-butyl acetate, isobutyl acetate, n-butanol, ethylene glycol, n-propanol, octanol, Cellosolve® acetate (ethylene glycol monomethyl ether monoacetate) and toluene. Of the solvents evaluated, the two mixtures (A&B), VM&P naphtha, Solvesso® 150, mineral spirits, xylene, n-butanol and octanol produced acceptable dispersions. Dispersions prepared using the other solvents hardened during the one week storage period or were two stiff and gum-like for use in a paint formulation.
EXAMPLE 3
A dispersion containing 60% by weight of tri-n-butyltin fluoride (TBTF) prepared as described in the preceding Example 1 using calcium chloride as the stabilizer, can be incorporated into a conventional paint formulation of the following composition:
______________________________________ Parts______________________________________Titanium dioxide 15.12Talc (magnesium silicate) 11.22Zinc oxide 7.08A vinyl chloride - vinyl acetate 11.16copolymer (VAGH)Rosin 3.732-butanone 20.31Xylene 18.84Bentonite clay 0.51Methanol (95%) 0.15TBTF.sup.1 dispersion As Required______________________________________ .sup.1 trin-butyltin fluoride
The solvent employed to prepare the dispersions is a mixture containing 64% special naphthalite, 12% ethyl benzene, 9% n-butyl acetate, 5% isobutyl acetate and 10% n-butanol. Special naphthalite is described in the preceding Example 1.
The amount of tri-n-butyltin fluoride dispersion employed is equivalent to 12% by weight of the compound in the formulation. The dispersion was blended together with the other components of the formulation to achieve a homogeneous mixture.
The paint can be evaluated using a Hegman N.S. gauge to determine "fineness" of the grind. A 0.003 inch (0.0076 cm)-thick film is applied to a metal surface using a draw-down blade and the texture of the resultant film is evaluated using the following scale:
1. Rough surface easily detected by rubbing a hand over the surface of the coating
2. 10-20 observable lumps uniformly distributed on paint surface
3. Several lumps visible
4. Smooth
The data from a typical paint evaluation are recorded in the following table. A Hegman fineness of 4 or 5 is considered acceptable.
______________________________________% CaCl.sub.2 Hegman Grind No. Film Rating______________________________________10 -- 45 -- 42.5 4 41 4-5 3-40.5 4-5 1-2______________________________________
The film prepared using a dispersion containing 0.5% by weight of calcium chloride and 60% tri-n-butyltin fluoride may be too rough in texture to be considered acceptable, however, this level of calcium chloride would be sufficient to stabilize dispersions containing less than 60% of the trialkyltin compound, for example about 50% by weight.
EXAMPLE 4
A typical red formulation suitable for use with the present dispersed form of tri-n-butyltin fluoride can be prepared using the following procedure:
______________________________________1. Combine the following ingredients using a high speed stirrer to obtain a uniform dispersion: Rosin (70% by weight in xylene) 4.89 parts A mixture containing bentonite clay 0.47 part and methanol 0.14 part2. Combine the mixture of (1) with cyclohexane 12.00 parts3. Add the pigments Red iron oxide 13.90 parts Talc 10.30 parts Zinc oxide 6.05 parts4. Add the film-forming polymer vinyl chloride/partially hydrolyzed vinyl acetate copolymer (available as VAGH from Union Carbide Corporation) as a 3% by weight solution in a 2-butanone-xylene mixture. 34.13 parts5. Add a dispersed form of tri-n- butyltin fluoride as described in the preceding Example 1. 17.65 parts6. Stir the mixture at high speed until the composition exhibits a fineness of 4 to 5 on the Hegman N.S. scale.______________________________________
EXAMPLE 5
A dispersion containing 50% by weight of TBTF prepared as described in the preceding Example 1 using calcium chloride as the stabilizer can be incorporated into a conventional paint formulation wherein the film-forming component is a chlorinated rubber.
______________________________________INGREDIENT PARTS______________________________________Red iron oxide 17.24Zinc oxide 8.09Talc (magnesium silicate) 7.30Bentonite Clay.sup.1 0.59Methanol 0.18Chlorinated natural rubber.sup.2 8.9Rosin 8.9Xylene 21.9TBTF dispersion 26.9 100.00______________________________________ Notes:? .sup.1 Bentone® 27, supplied by NL Industries. .sup.2 64-65% by weight of chlorine, viscosity = 17-25 cps, measured usin a 20% by weight solution in toluene at 25° C.?
The paint was prepared using the following procedure
1. Combine bentonite clay and methanol, mix thoroughly and combine with rosin; mix until homogeneous;
2. Add solvent (xylene) with the pigments to achieve the desired viscosity during dispersion;
3. Charge the pigments in order indicated and disperse to a 5 grind on the Hegman N.S. Scale:
Red Iron Oxide: 17.24
Zinc Oxide: 8.09
Talc: 7.03;
4. Charge the chlorinated rubber slowly with agitation until dissolved; and
5. Add the TBTF dispersion and mix to achieve a 4-5 grind on the Hegman N.S. Scale. | The tendency of dispersions containing trialkyltin fluorides in organic liquids to agglomerate is avoided by using as the dispersion medium specified organic liquids in combination with from 0.5 to 10%, based on the weight of the dispersion, of specified inorganic compounds. The choice of both organic liquid and inorganic compounds is critical to achieving long-term stability of the resultant dispersion. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is the U.S. national phase entry of PCT/CN2013/087977, with an international filing date of 27 Nov. 2013, which claims the benefit of Chinese Application Serial No. 201310169434.X, with a filing date of 9 May 2013, the entire disclosures of which are fully incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a polyvinyl chloride modifier, composition and preparation method thereof, especially to a polyvinyl chloride modifier with high elongation at break, a polyvinyl chloride composition with good toughness at low temperature and preparation method thereof.
BACKGROUND OF THE INVENTION
Polyvinyl chloride (PVC) resins generally have the following drawbacks: 1. Poor processability; 2. Poor impact strength at low temperature; 3. Poor heat stability; 4. Poor toughness at low temperature. At present, a variety of methods have been invented to improve the drawbacks of polyvinyl chloride resins, such as: adding additives to improve the processability of polyvinyl chloride resins; adding anti-impact modifiers to improve the anti-impact property of polyvinyl chloride resins at low temperature; adding heat stabilizers to improve the heat stability of polyvinyl chloride resins. However, the problem of the toughness of polyvinyl chloride resins at low temperature has not been well solved so far. And the problem of the toughness of polyvinyl chloride resins has become the major barrier for the development of polyvinyl chloride resins. For example, in the field of materials of the pipes for supplying water, polyvinyl chloride pipe materials have been gradually replaced by polyethylene (PE) pipe materials, mainly because bend deformations of polyvinyl chloride pipe materials buried under ground happen when terrain changes by time. As the toughness of polyvinyl chloride at low temperature is low, polyvinyl pipe materials will be easily broken by a slight bend; however, as the elongation at break for PE is high, PE pipe materials will not be broken even when the PE pipe materials bend because of the change of terrain. Therefore, for long-distance water supplying systems, PE pipe materials are usually preferred. Moreover, the major reason that wood materials cannot be replaced by polyvinyl chloride products is that polyvinyl chloride products will be easily cracked while inserting nails, and the fundamental reason for such phenomenon is the low elongation at break and the poor toughness of polyvinyl chlorides. Besides, cracking of the welding angles of the polyvinyl chloride doors and windows happens easily in winter when temperature is very low, which is also mainly because of the low elongation at break and the poor toughness of polyvinyl chlorides.
For a long period of time, there's a big misunderstanding in the field of modifying polyvinyl chlorides: mistakenly, it is considered that increasing the notch impact strength of polyvinyl chlorides is the same as increasing the toughness of polyvinyl chlorides; and mistakenly, it is considered that increasing the impact strengths of polyvinyl chlorides will increase the toughnesses of polyvinyl chlorides, thus increase the low temperature resistances of polyvinyl chlorides, therefore solve the problem of polyvinyl chloride pip materials such as cracking. Therefore, acrylates anti-impact modifiers (anti-impact ACR), methyl methacrylate-styrene-butadiene copolymers (MBS) anti-impact modifiers are usually used to increase the impact strengths of polyvinyl chlorides. However, although anti-impact ACR and MBS can largely increase the notch impact strengths of polyvinyl chlorides, they can hardly effectively improve the toughnesses of polyvinyl chlorides, especially the toughnesses under low temperature, which is not satisfying. Thus, currently, the elongations at break of polyvinyl chloride resins are not the same as or close to that of polyethylene, and the nail-holding abilities of polyvinyl chlorides are not the same as that of wood material.
SUMMARY OF THE INVENTION
While disregarding the above misunderstanding, the present invention discovered that the toughnesses of rigid non-plasticized polyvinyl chloride compositions are closely related to the elongations at break of the blend of polyvinyl chlorides and polyvinyl chloride toughening modifiers based on a great amount of studies. The higher the elongations at break of polyvinyl chloride compositions are, the better the toughnesses are. And the toughnesses of polyvinyl chloride compositions are associated with the elongations at break of polyvinyl chloride toughening modifiers, the higher the elongations at break of polyvinyl chloride toughening modifiers are, the higher the elongations at break of the non-plasticized polyvinyl chloride compositions are. Thus the elongations at break of polyvinyl chloride toughening modifiers must be improved to increase the toughnesses of the non-plasticized polyvinyl chloride compositions.
However, due to the limitation of the structure of synthesizing reactor of polyvinyl chloride toughening modifiers, it is very difficult to increase the elongations at break of the toughening modifiers when the elongation at break thereof is increased by 2200%. This is because the viscosity of the reaction solution is too high while producing toughening modifiers with high elongation, a very high stirring strength and a very high stirring rate are required to achieve the ideal dispersing effect of chlorine gas and reaction solution; in the reactors used previously, only stirring rakes that are fixed on top of the reactors and allow movements of the bottom are equipped. For such reactors, under a high stirring strength and a high stirring rate, the phenomenon that stirring rakes sway and reactors shake will happen easily, and so do industrial accidents, resulting in serious chlorine gas leak and safety problems. The present invention significantly increases the stirring strength by using modified reactors, and increases the elongations at break of toughening modifiers to above 2201% by using high density polyethylene (HDPE) with smaller particle size as raw materials.
The inventor developed rubber powders (toughening modifiers) that are well compatible with polyvinyl chloride resins and with very high elongations at break. To complete the present invention, said powders will be added into polyvinyl chloride resins to further increase the elongations at break of polyvinyl chloride compositions and further improve the toughnesses at low temperature of the polyvinyl chloride resins.
One of the objects of the invention is to provide a polyvinyl chloride composition, from which the polyvinyl chloride products prepared possess good toughness at low temperature.
Another object of the invention is to provide a preparation method of polyvinyl chloride compositions with simple process applied, and in the method, by adjusting reacting conditions, the elongations at break of rubber powders can be controlled, thus the toughnesses of the polyvinyl chloride compositions at low temperature can be controlled.
Yet another object of the invention is to provide a toughening modifier, which possesses a very high elongation at break.
Another object of the invention is to provide a preparation method of toughening modifiers with simple process, in the method, by adjusting reacting conditions, the elongations at break of rubber powders can be controlled,
The present invention can achieve the above objects by using the following technical solutions.
The present invention provides a polyvinyl chloride composition comprising the following components based on parts by weight:
(a) 100 parts polyvinyl chloride resin, and (b) 2-16 parts toughening modifier;
wherein said toughening modifier is rubber powders with an elongation at break greater than 2201% and 5-45 wt % weight percentage of chlorine;
said elongation at break is tested by GB/T528-2009;
the weight percentage of chlorine is tested by the method A of GB/T7139-2002.
Preferably, based on parts by weight, the polyvinyl chloride composition according to the present invention further comprises the following components:
(c) 0.5-5 parts stabilizer, (d) 0-50 parts filler, and (e) 0-50 parts wood powder, and (f) 0-10 parts polymers that comprise acrylates, and (g) 0-8 parts anti-impact modifier, and (h) 0-5 parts lubricant, and (i) 0-10 parts pigment.
According to the polyvinyl chloride composition of the present invention, preferably, said polyvinyl chloride resin is a polyvinyl chloride homopolymer or a polyvinyl chloride copolymer; wherein, polyvinyl chloride copolymer comprises 80-99.99 wt % vinyl chloride units and 0.01-20 wt % units that are formed by other units;
said other units are selected from one or more of vinyl acetate, propylene, styrene, C 1 -C 12 alkyl esters of methacrylic acid, C 1 -C 12 alkyl esters of acrylic acid.
According to the polyvinyl chloride composition of the present invention, preferably, said toughening modifier is selected from the group consisting of the following substances: chlorinated polyethylenes, copolymers of chlorinated polyethylene and (meth)acrylate or the mixtures of chlorinated polyethylene and (meth)acrylate polymer.
According to the polyvinyl chloride composition of the present invention, preferably, in said toughening modifiers, based on the total weight of the toughening modifier, the weight percentage of alkyl(meth)acrylate is 0-50 wt %.
The polyvinyl chloride composition according to the present invention, preferably,
said stabilizer is selected from organotin heat stabilizers, calcium-zin stabilizers or lead salt stabilizers;
said filler is selected from calcium carbonate, talc powder or white carbon black;
said polymers that comprise acrylates are selected from copolymers that comprise alkyl methacrylates and alkyl acrylates;
said anti-impact modifier is selected from copolymers that is formed by methyl methacrylate, styrene and butadiene.
said lubricant is selected from oxidized polyethylene wax, polyethylene wax, paraffin, stearic acid, glycerol monostearate, pentaerythritol stearate, pentaerythritol adipate or calcium stearate;
said pigment is selected from titanium white, carbon black, ultramarine pigment or fluorescent whitener.
The present invention further provides a preparation method for the above polyvinyl chloride compositions, said preparation method comprises preparation steps of toughening modifier, which can be specified as follows:
0.01-1.00 parts by weight of dispersing agent, 0.01-1.00 parts by weight of emulsifying agent are added to the reactor that is resistant to the erosion of chloric acid and is equipped with a stirring rake, then a dispersing medium is added, the total parts by weight of the dispersing agent, the emulsifying agent and the a dispersing medium are 250 parts by weight; then 15-40 parts by weight of high density polyethylene, 0.01-0.5 parts by weight of initiating agent are added, the temperature of the reaction materials are increased to 80-135° C. under the stirring rate of 30-300 rounds/min; then 5-25 parts by weight of chlorine gas are inlet, the inlet rate of chlorine gas must keep the reaction pressure to rise smoothly but not higher than the corresponding saturated steam pressure 0.05 MPa; the amount of the chlorine inlet must satisfy that below 50% of the total amount of chlorine gas are inlet below 135° C., and above 50% of the total amount of chlorine gas are inlet above 135° C.
According to the present invention, another preparation method for the above polyvinyl chloride compositions is provided, said preparation method comprises preparation steps of toughening modifier, which can be specified as follows:
(1) Preparation of Chlorinated Polyethylene:
0.01-1.00 parts by weight of dispersing agent, 0.01-1.00 parts by weight of emulsifying agent are added to the reactor that is resistant to the erosion of chloric acid and is equipped with a stirring rake, then a dispersing medium is added, the total parts by weight of the dispersing agent, the emulsifying agent and the dispersing medium are 250 parts by weight; then 15-40 parts by weight of high density polyethylene, 0.01-0.5 parts by weight of initiating agent are added, the temperature of the reaction materials are increased to 80-135° C. under the stirring rate of 30-300 rounds/min; then 5-25 parts by weight of chlorine gas are inlet, the inlet rate of chlorine gas must keep the reaction pressure to rise smoothly but not higher than the corresponding saturated steam pressure 0.05 MPa; the amount of the chlorine inlet must satisfy that below 50% of the total amount of chlorine gas are inlet below 135° C., and above 50% of the total amount of chlorine gas are inlet above 135° C.
(2) Preparation of Chlorinated Polyethylene and (Meth)Acrylate Copolymers
0.01-1.00 parts by weight of dispersing agent, 0.01-0.50 parts by weight of initiating agent and a dispersing medium are added to the reactor, wherein the total parts by weight of the dispersing agent, the initiating agent and the dispersing medium are 250 parts by weight; then 15-40 parts by weight of chlorinated polyethylene obtained in step (1), 0-0.50 parts by weight of emulsifying agent are added, the stirring rate is maintained at 30-300 rounds/min, then 1-40 parts by weight of alkyl(meth)acrylate is added after the temperature of the reaction materials are increased to 70-90° C., the reaction temperature is maintained at 80-85° C., after 2-5 hours of reaction, the temperature is cooled to below 40° C.
According to the preparation methods of the polyvinyl chloride compositions of the present invention, preferably, the medium interface of the reactor is made of titanium-palladium alloy, zirconium or tantalum; said stirring rake is a zirconium-made stirring rake that is resistant to the erosion of chloric acid and the top and bottom ends of the stirring rake are fixed to the top and bottom of the reactor respectively and it can rotate freely.
According to the preparation methods of the polyvinyl chloride compositions of the present invention, preferably, the average particle size D50 of said high density polyethylene is 40-140 μm;
the average particle size is obtained by Taylor Sieve Method, the measurement is made specifically as follows: 200 g high density polyethylene is screened for 10 minutes by vibrating screening on different sieves, then the weight of the particles on the sieve is weighed, the particle size when particles that are 50% of the weight of the particles are screened is chosen to be the average particle size D50.
According to the preparation methods of the polyvinyl chloride compositions of the present invention, preferably, the melt index of said high density polyethylene is 0.2-4.0 g/10 min; said melt index is measured by ASTM D1238, the temperature is 190° C., the load is 5.0 kg.
The present invention also provides a toughening modifier, said toughening modifier is selected from chlorinated polyethylene, or copolymer of chlorinated polyethylene and (meth)acrylate; said toughening modifier is rubber powders with an elongation at break higher than 2201% and 5-45 wt % weight percentage of chlorine;
said elongation at break is measured by GB/T528-2009;
the weight percentage of chlorine is measured by the method A of GB/T7139-2002.
The present invention also provides a preparation method of the above toughening modifier, said toughening modifier is chlorinated polyethylene, and preparation steps can be specified as follows:
0.01-1.00 parts by weight of dispersing agent, 0.01-1.00 parts by weight of emulsifying agent are added to the reactor that is resistant to the erosion of chloric acid and is equipped with a stirring rake, then a dispersing medium is added, the total parts by weight of the dispersing agent, the emulsifying agent and the dispersing medium are 250 parts by weight; then 15-40 parts by weight of high density polyethylene, 0.01-0.5 parts by weight of initiating agent were added, the temperature of the reaction materials are increased to 80-135° C. under the stirring rate of 30-300 rounds/min; then 5-25 parts by weight of chlorine gas are initially inlet, the inlet rate of chlorine gas must keep the reaction pressure to rise smoothly but not higher than the corresponding saturated steam pressure 0.05 MPa; the amount of the chlorine inlet must satisfy that below 50% of the total amount of chlorine gas are inlet below 135° C., and above 50% of the total amount of chlorine gas are inlet above 135° C.
The present invention also provides another preparation method of the above toughening modifier, said toughening modifier is a copolymer of chlorinated polyethylene and (meth)acrylate, preparation steps are specified as follows:
(1) Preparation of Chlorinated Polyethylene
0.01-1.00 parts by weight of dispersing agent, 0.01-1.00 parts by weight of emulsifying agent are added to the reactor that is resistant to the erosion of chloric acid and is equipped with a stirring rake, then a dispersing medium is added, the total parts by weight of the dispersing agent, the emulsifying agent and the dispersing medium are 250 parts by weight; then 15-40 parts by weight of high density polyethylene, 0.01-0.5 parts by weight of initiating agent are added, the temperature of the reaction materials are increased to 80-135° C. under the stirring rate of 30-300 rounds/min; then 5-25 parts by weight of chlorine gas are inlet, the inlet rate of chlorine gas must keep the reaction pressure to rise smoothly but not higher than the corresponding saturated steam pressure 0.05 MPa; the amount of the chlorine inlet must satisfy that below 50% of the total amount of chlorine gas are inlet below 135° C., and above 50% of the total amount of chlorine gas are inlet above 135° C.
(2) Preparation of Chlorinated Polyethylene and (Meth)Acrylate Copolymers
0.01-1.00 parts by weight of dispersing agent, 0.01-0.50 parts by weight of initiating agent and dispersing medium are added to the reactor, wherein the total parts by weight of the dispersing agent, the initiating agent and the a dispersing medium are 250 parts by weight; then 15-40 parts by weight of chlorinated polyethylene obtained in step (1), 0-0.050 parts by weight of emulsifying agent are added, the stirring rate is maintained at 30-300 rounds/min, then 1-40 parts by weight of alkyl(meth)acrylate is added after the temperature of the reaction materials are increased to 70-90° C., the reacting temperature is maintained at 80-85° C., after 2-5 hours of reaction, the temperature is cooled to below 40° C.
The present invention fundamentally solves the defects of low elongation at break and poor toughness at low temperature of polyvinyl chloride products, which allow the elongations at break of non-plasticized polyvinyl chloride products to reach above 233% while maintaining the mechanical property of polyvinyl chloride products unchanged, which fundamentally solves the problem of poor toughness at low temperature and easily stress cracked of polyvinyl chloride products, thus achieving a replacement of materials such as polyethylene, wood and metal by polyvinyl chlorides.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, (meth)acrylates represent acrylates and/or methacrylates. (Meth)acrylic acid represent acrylic acid and/or methyl acrylic acid. In the present invention, unless otherwise defined, “parts” and “%” are all based on weight.
Impact strength and toughness are two different concepts, but in the prior art, it has been taught for a long time that toughness can be improved by increasing impact strength. The essence of impact strength is the ability to transform impact energy into heat energy when the material is impacted; whereas the essence of toughness is elongation at break and tensile strength. The larger the tensile strength is and the higher the elongation at break, the better the toughness of the material is. Therefore, toughness can be understood as the ability of quickly generating deformation and relieving stress when material is under stress or there's stress inside. In the present invention, it is discovered that impact strength is closely related to phase structure of material, toughness is closely related to elongation at break of material, thus elongation at break must be increased in order to increase toughness of material.
Compared with traditional polyvinyl chloride compositions, the present invention can further improve elongations at break of polyvinyl chloride products by adding high molecular polymers that are well compatible with polyvinyl chloride resins and with very high elongations at break into polyvinyl chloride resins.
<Polyvinyl Chloride Compositions>
The polyvinyl chloride compositions of the present invention comprise polyvinyl chloride resins and toughening modifiers. Optionally, the present invention can also comprise one or more other additives including the following components: stabilizers, fillers, wood powder, polymers that comprise acrylates, anti-impact modifiers, lubricants, pigments. Preferably, the polyvinyl chloride compositions of the present invention comprise polyvinyl chloride resins, toughening modifiers and stabilizers. More preferably, the polyvinyl chloride compositions of the present invention comprise polyvinyl chloride resins, toughening modifiers, stabilizers and anti-impact modifiers. More preferably, the polyvinyl chloride compositions of the present invention comprise polyvinyl chloride resins, toughening modifiers, stabilizers, anti-impact modifiers and lubricants.
Preferably, the elongations at break of the polyvinyl chloride compositions of the present invention can reach to above 233%, and above 250%, even above 300%. Said elongations at break are measured according to GB/T 1040.1-2006. The experiment are carried out under the conditions according to the regulations of GB/T1040.2-2006, the samples are 18 type dumb-bell shape samples. The stretching velocity of the experiment machine is 5 mm/min. The experiment temperature follows the regulation of GB/T2918-1998, the temperature is 24° C.-25° C.; the relative humidity is 50±5%.
The characteristics of the present invention lie in using rubber powders that have the elongation at break greater than 2201% and are well compatible with polyvinyl chloride resins as the toughening modifiers for polyvinyl chloride resins, said rubber powders can be any component as long as it can be well compatible with polyvinyl chloride resins and can be homogeneously dispersed into polyvinyl chloride resins under general processing conditions. For example, it can be chlorinated polyethylene, graft copolymer of chlorinated polyethylene and (meth)acrylates, interpenetrating copolymer networks of chlorinated polyethylene and (meth)acrylate or compositions of chlorinated polyethylene and (meth)acrylate copolymers etc. The elongation at break of polyvinyl chlorides will be improved largely without significantly influencing the other physical and chemical properties of polyvinyl chlorides as long as the elongations at break of the above modifiers are higher than 2201%.
The polyvinyl chloride toughening modifier of the present invention is a component that is added to increase the elongation at break of polyvinyl chloride resin, and is a kind of rubber powders that are well compatible with polyvinyl chloride resins, the major components of the polyvinyl chloride toughening modifier can be chlorinated polyethylene, copolymer of chlorinated polyethylene and alkyl(meth)acrylate, or compositions of chlorinated polyethylene and alkyl(meth)acrylate polymers. The importance is that the elongations at break of these rubber powders are relatively high, which are higher than 2201%.
There's no special limitation for the methods for the preparation of the polyvinyl chloride resin compositions of the present invention, for example, said methods can be carried out as long as polyvinyl chloride resins, toughening modifiers and other additives that can be added optionally are homogeneously mixed. Preferably, the preparation method of the composition can be mixing polyvinyl chlorinated resins, toughening modifiers and other additives that can be optionally added with high-speed stirrer under suitable temperature then cooling the mixture with low-speed stirrer to obtain polyvinyl chloride compositions.
There's no specially limitation for the method for forming the polyvinyl chloride resin composition of the present invention, said composition can be formed by general methods such as extrusion molding or injection molding.
<Polyvinyl Chloride Resin>
There's no special limitation for polyvinyl chloride resin of the present invention, any common polyvinyl chloride resins can be used in the present invention. The polyvinyl chloride resin of the present invention can be polyvinyl chloride homopolymers or polyvinyl chloride copolymers. Wherein preferred polyvinyl chloride copolymer may comprises 80-99.99 wt % chlorinated ethylene unit and 0.01-20 wt % units that are formed by other units. The preferred polyvinyl chloride copolymer can be obtained by the copolymerization of 80-99.99 wt % chlorinated ethylene units with 0.01-20 wt % other units that can be copolymerized with chloroethylene. Here the above preparation methods won't be further described as they are those that are known in the art. The other units that can be copolymerized with chloroethylene can be vinyl acetate, propylene, styrene, alkyl(meth)acrylate (for example, C 1 -C 12 alkyl methacrylates) or other vinyl monomer. These monomers can be used separately or in combination, wherein the alkyl of the alkyl ester thereof is preferably C 1 -C 12 alkyls, C 1 -C 5 alkyls and C 1-3 alkyls. The examples of alkyls include but are not limited to methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, hendecyl, dodecyl.
There's not special limitation for the average degree of polymerization of the polyvinyl chloride of the present invention. For example, polyvinyl chloride resin with the degree of polymerization between 600-1300, preferably between 700-1100, most preferably between 800-1000 can be used. However, if the degree of polymerization is lower than 600, the mechanical property of the polyvinyl chloride products will be largely decreased; and if the degree of polymerization is higher than 1300, general methods cannot be used for processing.
Preferably, the polyvinyl chloride resins of the present invention are homopolymers or copolymers that comprise no less than 80 wt % chloroethylene monomer units and no more than 20 wt % vinyl acetate, propylene, styrene or acrylate monomer units. If the weight percentage of chloroethylene monomer units is lower than 80 wt %, the mechanical property of the polyvinyl chloride resin will be decreased. Preferably, the content of chloroethylene monomer units is above 80 wt %, preferably above 90 wt %, most preferably above 95 wt %, based on the total monomer units of polyvinyl chloride resin. Preferably, the degree of polymerization of the above polyvinyl chloride resin is between 600-1300.
<Toughening Modifiers>
The polyvinyl chloride composition of the present invention comprises, based on (a) 100 parts by weight of polyvinyl chloride resin, (b) 2-16 parts by weight of toughening modifier. When the amount of the toughening modifier is lower than 2 parts by weight, the elongation of polyvinyl chloride will largely decrease; when the amount of the toughening modifier is higher than 16 parts by weight, the processability of the polyvinyl chloride composition will largely decrease. Based on (a) 100 parts by weight of polyvinyl chloride resin, the amount of use of toughening modifier is preferably 5-14 parts by weight, most preferably 7-12 parts by weight.
The toughening modifier used in the present invention is rubber powders. The elongation at break for the toughening modifier of the present invention is larger than 2201%, preferably 2220%-3500%, more preferably 2300%-2950%. In this case, advantageously, the elongation at break of polyvinyl chloride composition and thus the toughness at low temperature thereof will be improved. Here the elongation at break is measured by GB/T528-2009.
The weight percentage of chlorine of the toughening modifier used in the present invention is 5-45 wt %. The chlorine weight percentage represents the percentage of the weight of chlorine elements in the total weight of toughening modifier. The chlorine weight percentage of the present invention is measured by the method A of GB/T7139-2002 (The measurement of the chlorine content of plastic chloroethylene homopolymers and copolymers). When the content of chlorine is lower than 5 wt %, the toughening modifier is not compatible with polyvinyl chloride resin and cannot be dispersed homogeneously with polyvinyl chloride resin to form net structure. In such circumstance, the property of the polyvinyl chloride composition will be largely decreased. If the chlorine content is beyond 45 wt %, then the elongation at break of the toughening modifier will be largely decreased, and the hardness will be greatly increased, and the mechanical property of the polyvinyl chloride composition will be largely decreased. The chlorine weight percentage of the toughening modifier of the present invention is preferably 10-40 wt %, most preferably 25-35 wt %.
There's no special limitation for the types of the toughening modifiers of the present invention, any polymers with an elongation at break larger than 2201% and 5-45% chlorine weight percentage can be used. Preferably, toughening modifiers used in the present invention can be selected from those polymers that can be mixed with polyvinyl chloride resins and dispersed homogeneously. More preferably, toughening modifiers used in the present invention can be selected from the group consisting of the following substances: chlorinated polyethylenes, copolymers of chlorinated polyethylene and (meth)acrylate or the compositions of chlorinated polyethylene and (meth)actylate polymer. More preferably, the toughening modifiers used in the present invention are selected from chlorinated polyethylene, graft copolymers of chlorinated polyethylene and (meth)actylate, interpenetrating polymer networks of chlorinated polyethylene and (meth)actylates, or compositions of chlorinated polyethylene and (meth)acrylate copolymers. These polymers can be dispersed completely and homogeneously with polyvinyl chloride resin under general processing conditions. The toughening modifiers of the present invention are not limited to the above polymers, the polymers that can be mixed with polyvinyl chloride resins and dispersed homogeneously under general processing conditions and with an elongation at break larger than 2201% can also be used.
In the toughening modifier of the present invention, based on the total weight of the toughening modifier, the weight percentage of alkyl(meth)acrylate is 0-50 wt %. When the weight percentage of alkyl(meth)acrylate is greater than 50%, the powder flowdability of the material will decrease, the toughening modifier cannot be homogeneously mixed with polyvinyl chloride resin. Therefore, the content of alkyl(meth)acrylate is 0-50 wt %, preferably 5-30%, most preferably 5-15 wt %. Wherein the alkyls in the alkyl esters comprise but are not limited to C 1 -C 12 alkyls. The examples of alkyls can be but are not limited to methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, hendecyl, dodecyl.
As toughening modifiers added into the polyvinyl chloride resin compositions, the average particle sizes (D50) of the toughening modifiers are preferably 160-650 μm, more preferably 200-600 μm, even more preferably 230-550 μm. The smaller the particle sizes of the toughening modifiers are, the better the dispersities of the toughening modifiers in the polyvinyl chloride resins are, the better the net structures formed are, the longer the elongations of the polyvinyl chloride resin compositions are, the better the toughnesses of the polyvinyl chloride products are. However, if the particle sizes are too small, the powders will easily agglomerate, resulting in that the formed products cannot be used; if the powders are too large, then the toughening agent cannot be dispersed completely into polyvinyl chloride resins. The particle size of the toughening modifier is measured by Taylor Sieve Method. The measurement method can be specified as follows: 200 g sample is screened for 10 minutes by vibrating screening on different sieves, then the weight of the particles on the sieve is weighed, the particle size when particles that are 50% of the weight of the particles are screened is chosen to be the average particle size D50.
<Other Additives>
The polyvinyl chloride compositions of the present invention can comprise, based on (a) 100 parts by weight of polyvinyl chloride resin, (c) 0.5-5 parts by weight, preferably 1-4 parts by weight, more preferably 2-3 parts by weight of stabilizer. There's not special requirement for the stabilizers used in the present invention. Preferably, the stabilizer used in the present invention can be organotin heat stabilizer, calcium-zinc stabilizer or lead salt stabilizer etc. The calcium-zinc stabilizer comprises components such as calcium salt, zinc salt, lubricant, antioxidant as the major components and said stabilize is synthesized by a complex technique which won't be described here.
The polyvinyl chloride compositions of the present invention can comprise, based on (a) 100 parts by weight of polyvinyl chloride resin, (d) 0-50 parts by weight, preferably 1-40 parts by weight, more preferably 5-30 parts by weight of filler. There's not special requirement for the types of the fillers used in the present invention, the filler is preferably inert, i.e. the filler doesn't react with the component in the polyvinyl chloride composition. Preferably, the filler can be calcium carbonate, talc powder, carbon black or white carbon black etc.
The polyvinyl chloride compositions of the present invention can comprise, based on (a) 100 parts by weight of polyvinyl chloride resin, (e) 0-50 parts by weight, preferably 1-40 parts by weight, more preferably 5-30 parts by weight of wood powders. Any wood powders can be used in the present invention.
The polyvinyl chloride compositions of the present invention can comprise, based on (a) 100 parts by weight of polyvinyl chloride resin, (f) 0-10 parts by weight, preferably 0.2-5.0 parts by weight, more preferably 0.5-2.0 parts by weight of polymers that comprise acrylates. Generally, polymers that comprise acrylates can improve the processability of polyvinyl chloride compositions, the more the amount of use is, the better the processability is, but the cost will also be increased. Therefore, under the circumstance that the processability of the polyvinyl chloride compositions can be ensured, the amount of use is the less the better. The polymer that comprises acrylates of the present invention represents polymers comprising (meth)acrylate monomer units. The polymers comprising acrylates of the present invention is preferably the polymers that comprise alkyl methacrylates and alkyl acrylates, wherein the alkyls in the alkyl ester are preferably C 1 -C 12 alkyls, C 1 -C 5 alkyls, C 1 -C 3 alkyls. The examples of the alkyls comprise but are not limited to: methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, hendecyl, dodecyl.
The polyvinyl chloride compositions of the present invention can comprise, based on (a) 100 parts by weight of polyvinyl chloride resin, (g) 0-8 parts by weight, preferably 1-6 parts by weight, more preferably 2-4 parts by weight of anti-impact modifier. When the amount of use of anti-impact modifier is larger than 8 parts, the tensile strength, the hardness, the Vicat softening point will decrease greatly. There's no special limitation for the types of the anti-impact modifiers of the present invention, the materials that can increase the notch impact strength of polyvinyl chloride can be used. Preferably, the anti-impact modifier of the present invention can be acrylate anti-impact modifier, terpolymers of methactylate-styrene-butadiene (MBS) etc.
The polyvinyl chloride compositions of the present invention can comprise, based on (a) 100 parts by weight of polyvinyl chloride resin, (h) 0-5 parts by weight, preferably 0.1-3 parts by weight, more preferably 0.5-2 parts by weight of lubricants. The lubricants of the present invention can be selected from one or more oxidized polyethylene wax, polyethylene wax, paraffin, stearic acid, monoglyceric stearat, pentaerythrite stearate, pentaerythrite adipate or calcium stearate.
The polyvinyl chloride compositions of the present invention can comprise, based on (a) 100 parts by weight of polyvinyl chloride resin, (i) 0-10 parts by weight, preferably 1-8 parts by weight, more preferably 2-5 parts by weight of pigments. Preferably, the pigments of the present invention can be selected from one or more of titanium white, carbon black, ultramarine pigment or fluorescent whitener.
<Preparation of Toughening Modifiers>
There's no special limitation for the preparation method of the toughening modifier used in the present invention, any rubber powder that have an elongation at break larger than 2201% and with a chlorine weight percentage of 5-45% can be used. The preparation method of the toughening modifiers will be illustrated below.
(1) Polyvinyl Chloride can be Prepared According to the Following Method:
0.01-1.00 parts by weight of dispersing agent, 0.01-1.00 parts by weight of emulsifying agent are added to the reactor that is resistant to the erosion of chloric acid and is equipped with a stirring rake with both the top and the bottom ends fixed and a high stirring intensity, then a dispersing medium is added, the total parts by weight of the three auxiliary raw material are 250 parts by weight; then 15-40 parts by weight of high density polyethylene, 0.01-0.5 parts by weight of initiating agent are added, the temperature of the reaction materials are increased to 80-135° C. under the stirring rate of 30-300 rounds/min (the homogeneous mixing of the reaction solution and chlorine gas can be ensured by adjusting the stirring rate), then 5-25 parts by weight of chlorine gas are inlet, the inlet rate of chlorine gas must keep the reaction pressure to rise smoothly but not higher than the corresponding saturated steam pressure 0.05 MPa; the amount of the chlorine inlet must satisfy that below 50% of the total amount of chlorine gas are inlet below 135° C., and above 50% of the total amount of chlorine gas are inlet above 135° C. The rubber powder with an elongation at break larger than 2201% is obtained by centrifugation and drying. Preferably, below 50% of the total amount of chlorine gas can be inlet first within 1 hour and the temperature can be increased to 135-145° C., then keep the reacting temperature above 135° C., the rest chlorine gas that represents above 50% of the total amount of chlorine gas are inlet.
The chlorinated polyethylene rubber powders obtained in step (1) can be directly used to toughen and modify polyvinyl chloride resins at low temperature. Besides, copolymers of chlorinated polyethylene and (meth)acrylate can be obtained by grafting or interpenetrating network copolymerization between the chlorinated polyethylene rubber powders obtained in the above step (1) and alkyl(meth)acrylate, to form rubber powders with an elongation at break larger than 2201%.
(2) Copolymers of Chlorinated Polyethylene and (Meth)Acrylate are Prepared According to the Following Method:
0.01-1.00 parts by weight of dispersing agent, 0.01-0.50 parts by weight of initiating agent and a dispersing medium are added to the reactor, the total parts by weight of the three auxiliary raw materials are 250 parts by weight; then 15-40 parts by weight of chlorinated polyethylene obtained in step (1), 0-0.50 parts by weight of emulsifying agent are added, the stirring rate is maintained at 30-300 rounds/min, then 1-40 parts by weight of alkyl(meth)acrylate is added after the temperature of the reaction materials is increased to 70-90° C., the reaction temperature is maintained at 80-85° C., after 2-5 hours of reaction, the temperature is cooled to below 40° C. The polymer rubber particle with an elongation at break larger than 2201% is obtained by centrifugation and drying.
While producing the toughening modifiers of the present invention, the average particle size Dn (preferably D50) of the above high density polyethylene can be between 40-140 μm. When the particle size of the high density polyethylene is smaller than 40 μm, the viscosity of the reaction solution during the process of chlorination is too large, and it is difficult to stir the reaction, and the reaction solution is poorly mixed, and the chlorinated reaction can hardly be carried out homogeneously. If the average particle size of the high density polyethylene is larger than 140 μm, even the viscosity of the reaction solution is not high, as chlorine gas is hard to enter HDPE, the rate of reaction of chlorination is slowed, and the homogeneity of chlorination is decreased, resulting in the decrease of the property of toughening modifier. The average particle size D50 of the HDPE used in the production of the toughening modifier of the present invention is between 40-140 μm, preferably between 50-120 μm, most preferably between 60-100 μm.
The above particle sizes are obtained by Taylor Sieve Method, the measurement method can be specified as follows: 200 g high density polyethylene is screened for 10 minutes by vibrating screening on different sieves, then the weight of the particles on the sieve is weighed, the particle size when the particles that are 50% of the weight of the particles are screened is chosen to be the average particle size D50.
When producing the toughening modifier of the present invention, the melt index of the above high density polyethylene (HDPE) is 0.2-4.0 g/10 min. When the melt index is lower than 0.2 g/10 min, the compatibility between the toughening modifier and the polyvinyl chloride resin will be decreased and the toughening modifier cannot be dispersed into polyvinyl chloride resin, thus the mechanical property of the material will be decreased; when the melt index is higher than 4.0 g/10 min, then the mechanical property of the polyvinyl chloride composition, such as the tensile strength will be largely decreased. Therefore, the melt index of HOPE is 0.2-4.0 g/10 min, preferably 0.3-3.0 g/10 min, more preferably 0.4-1.0 g/10 min. The above melt index is measured with ASTM 01238.
While producing the toughening modifier of the present invention, the material of the reactor of the present invention is preferably the explosive composite material. The medium interface of the above reactor is made of a material that is resistant to the erosion of chloric acid, for example, the material can be selected from titanium-palladium alloy, zirconium material or tantalum material. The bonding layer is an explosive composite bonding layer that is made purely by titanium, the bearing layer is made of carbon steel. The top and bottom ends of the stirring rake(s) of the reactor are fixed on the top and bottom of the reactor. Said stirring rake(s) can stir freely at a high speed. The stirring rake is a high stirring strength rake that is resistant to the erosion of chloric acid, such as stirring rake made of zirconium material. The inventor found that while producing chlorinated polyethylene with high elongation at break, the viscosity of the reaction liquid is very high, thus a very high stirring intensity and a very high stirring rate are required to ensure that chlorine gas is homogeneously mixed with reacting liquid, however, for those commonly used stirring rakes that are fixed to the top of the reactors, the stirring rakes will easily sway, thus resulting in the violent shaking of the reactor and the damage of the reactors. Therefore, stirring rakes with both the top and the bottom ends fixed and a high stirring intensity are preferably used.
In the preparation processes of the toughening modifiers of the present invention, the dispersing medium that is generally used is water.
In the preparation processes of the toughening modifiers of the present invention, the type of dispersing agents is not specially limited. For example, the dispersing agent can comprise copolymer of water-soluble alkyl(meth)acrylate and (meth)acrylate. Moreover, the dispersing agent can comprise the mixture of copolymer of water-soluble alkyl(meth)acrylate and (meth)acrylate and white carbon black, wherein the alkyls in the alkyl esters are preferably C 1 -C 12 alkyls, C 1 -C 5 alkyls and C 1 -C 3 alkyls. The examples of alkyls can be but are not limited to methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, hendecyl, dodecyl.
In the preparation processes of the toughening modifiers of the present invention, the type of emulsifying agent is not specially limited. For example, the emulsifying agent can comprise polyoxyethylene alkyl ether, polyoxyethylene aliphatate or lauryl sodium sulfate.
In the preparation processes of the toughening modified of the present invention, the initiating agent can be water-soluble polymerization initiating agent and oil-soluble polymerization initiating agent. For example, the initiating agent can be inorganic initiating agent (such as peroxysulphate), organic peroxides or azo compound. These initiating agents can be used separately or in combination with an oxidation-reduction system that is composed of sulfites, thiosulfate, formaldehyde sodium sulphoxylate. In the initiating agents of the present invention, the persulfates can be selected from sodium persulfate, potassium persulfate, ammonium persulfate etc. The organic peroxides can be selected from tert-butyl hydroperoxide, benzoyl peroxide etc.
The toughening modifiers with the required elongation at break will be obtained by adjusting suitable stirring intensity, particle sizes of raw materials, reaction temperature, rate of chlorine inlet and amount of the chlorine inlet according to use purposes and reaction conditions.
In summary, the toughening modifiers of the present invention can be obtained by a one-step, two-step or multi-step reaction. If a two-step reaction or a multi-step reaction is applied, it should be confirmed that a previous step must be completed before adding the reactants of the next step. Accordingly, the reactants of each step will not mix with the reactants of the following step.
The obtained polymer rubber particles are centrifuged, washed with water and dried by common methods according to the requirement after the reaction is completed.
The present invention will be illustrated in detail by the examples and the comparative examples below, unless otherwise defined, all the “parts” and “%” are based on weight. It should be understood that the present invention shall not be limited to those examples.
<Testing Method>
(1) Test of Elongations at Break of Toughening Modifiers.
The test is carried out according to GB/T 528-2009 (test of strain performances of tensile stress of vulcanized rubber or thermoplastic rubber). The sample is prepared according to the regulations of the section 5.9 of HG/T2704-2010: pelleting temperature 85±2° C., mixing time 3 min, compression molding temperature 130° C., temperature is kept constant for 5 min, and pressure is maintained for 2 min. A type 1 dumb-bell shape sample is used, stretching velocity of the tensile machine is 500 mm/min. According to the regulations of GB/T2941-2006, the temperature of the test is 24-25° C.; and the relative humidity is 50±5%.
The tensile machine is the modified universal test machine of the type UTM-1422 (Jin Jian Testing maching Ltd., Chengde), the specific parameters are as follows:
Type UTM-1422 Testing Maximum testing force 10 kN parameters Degree of testing machine 0.5 degree Measuring range of testing forces 0.2%-100% FS Relative error of the indicating ±0.5% value of testing forces Resolution capacity of testing 1/200000 forces Measuring range of deformation 0.2-100% FS Relative error of the indicating Within ±0.50% value of deformations Resolution capacity of 1/200000 deformations Measuring range of gross 5-800 mm distortions Relative error of the indicating Within ±0.50% value of gross distortions Resolution capacity of gross 0.0125 mm distortions Test of bending depletion 15 mm extensometer Resolution capacity of bending 0.001 mm depleting extensometer Accuracy of bending depleting 0.005 mm extensometer Relative error of the indicating Within ±0.50% value of beam displacements Resolution capacity of 0.001 mm displacements Control Adjusting range of force control 0.005-5% FS/S parameters rates Relative error of force control Within ±1% of the set point rates Adjusting range of deformation 0.02-5% FS/S rates Relative error of deformation Within ±2% of the set point when the rate is control rates less than 0.05% FS; within ±0.5% of the set point when the rate is larger than or equal to 0.05% Adjusting range of beam rates 0.001-500 mm/min Beam rates; relative error Within ±1.0% of the set point when the rate is less than 0.05 mm/min; within ±0.5% of the set point when the rate is larger than or equal to 0.05 m/min; Control range of constant forces, 0.5%-100% FS constant deformations, constant displacements Control accuracy of constant Within ±0.1% of the set point when the set forces, constant deformations, point is greater than or equal to 10% FS; within constant displacements ±1% of the set point when the set point is less than 10% FS; Effective testing width 400 mm Maximum stretch stroke 1400 mm
(2) Test of Elongations at Break of Polyvinyl Chloride Compositions.
The test is carried out according to GB/T 1040.1-2006 (Test of the tensile performance of plastics, Part 1: General rules). The experiment conditions are carried out according to the regulations of GB/T1040.2-2006 (Test of the tensile performance of plastics, Part 2: Experiment condition of molded plastics and extruded plastics). The sample is a 1B type dumb-bell shape sample. The stretching velocity of the tensile machine is 5 mm/min. According to the regulations of GB/T2918-1998, the temperature of the test is 24-25° C.; and the relative humidity is 50±5%.
(3) Test of Reaction Conversions
Conversion of the reaction is calculated according to the following equation:
Reaction conversion=(Weight of the generated rubber plastics/the amount of the reactant fed)×100%; with the amount of chlorine gas calculated based on half of the actual feeding amount when chlorine gas is one of the reactant.
(4) Test of Powder Sizes
The test is carried out according to Taylor Sieve Method. The specific test method is as follows: 200 g sample is screened for 10 minutes by vibrating screening on different sieves, then the weight of the particles on the sieve is weighed, the particle size when the particles that are 50% of the weight of the particles are screened is chosen to be the average particle size D50.
(5) Test of the Melt Index of High Density Polyvinyl Chloride (HDPE)
The test is carried out using ASTM 01238, the temperature is 190° C., the load is 5.0 kg, the unit of melt index is g/10 min.
<Molding Conditions and Standards of Extruding Machine>
The temperature of the sections of extruding machine that used for extruding polyvinyl chloride sheets: C1=165° C., C2=175° C., C3=185° C. The temperature of die head=185° C.
The standards of extruding machine are as follows:
Screw: length-to-diameter ratio (L/D)=25, compression ratio=2.5, rotating rate of main engine=60 rounds/min.
Die head: width=100 mm, thickness=3 mm.
Example 1
(1) Preparation of Toughening Modifiers
0.28 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is resistant to the erosion of chloric acid and is equipped with a zirconium-made stirring rake with both top and bottom ends fixed to the reactor, 0.04 parts of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 35 parts of high density polyethylene with the average particle size D50 of 95 μm, 0.025 parts of benzoyl peroxide were added. After the temperature of the reaction materials were increased to 80° C. under the stirring rate of 85 rounds/min, 42 parts by weight of chlorine gas was inlet, then the temperature was increased to 135° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet during the temperature increasing was 19 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The temperature was kept at 135-138° C. after reaching 135° C., the rest 23 parts of chlorine gas was inlet at the rate of 23 parts/hour. The rubber powder with an elongation at break of 2230% was obtained after centrifugation and drying (sample 1). The conversion of the reaction was 99.5%, the content of chlorine (i.e. the weight percentage of chlorine, the contents of chlorine below are represented in the same way) was 37.3%, the average particle size D50 of the powder was 190 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
100 parts of polyvinyl chloride (S-1000, the average degree of polymerization is 1000, produced by QILU subsidiary of SINOPEC), 8 parts of the above rubber powder (sample 1), 3 parts of MBS (RK-56P), 5 parts of calcium carbonate, 5 parts of titanium dioxide, 2 parts of methyltin heat stabilizer (the content of tin is 18%), 1 part of calcium stearate, 0.5 part of paraffin (the melt point is 60° C.), 0.5 part of polyethylene wax (the melt point is 110° C.) were added to a high-speed mixer, then stirring was started, the temperature inside was increased to 120° C. Polyvinyl chloride composition powders were obtained after cooling. The composition was extruded by the extruding machine to obtain polyvinyl chloride composition sheet products. The elongation at break was measured, the results of the experiment can be seen in table 1.
Example 2
(1) Preparation of Toughening Modifiers
Water, 0.1 part of polymethyl methacrylate-acrylate copolymer dispersing agent, 0.05 part of benzoyl peroxide were added to a reactor equipped with a stirring rake, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. 30 parts of sample 1, 0.1 part of dodecyl sodium sulfate were added then. Under the stirring rate of 60 rounds/min, nitrogen gas was inlet and the temperature of the reaction material was increased to 80° C. simultaneously. Then 3 parts of butyl acrylate and 1 part of methyl methacrylate were added, the temperature was kept at 80-85° C., after 3 hours of reaction, the temperature was cooled to below 40° C. The rubber powder with an elongation at break of 2260% was obtained after centrifugation and drying (sample 2).
The conversion of the reaction was 98.3%, the average particle size D50 of the powder was 310 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride compositions and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Example 3
(1) Preparation of Toughening Modifiers
0.28 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is resistant to the erosion of chloric acid and is equipped with a zirconium-made stirring rake with both top and bottom ends fixed to the reactor, 0.04 parts of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 35 parts of high density polyethylene with the average particle size D50 of 95 μm, 0.025 parts of benzoyl peroxide were added. After the temperature of the reaction material was increased to 85° C. under the stirring rate of 85 rounds/min, 42 parts of chlorine gas was inlet, then the temperature was increased to 135° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet while increasing the temperature was 19 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The temperature was kept at 135-138° C. after reaching 135° C., and the rest 23 parts of chlorine gas was inlet at the rate of 23 parts/hour. The rubber powder with an elongation at break of 2320% was obtained after centrifugation and drying (sample 3).
The conversion of the reaction was 99.3%, the content of chlorine was 37.3%. The average particle size D50 of the powder was 200 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride compositions and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Example 4
(1) Preparation of Toughening Modifiers
0.28 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is resistant to the erosion of chloric acid and is equipped with a zirconium-made stirring rake with both top and bottom ends fixed to the reactor, 0.04 parts of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 35 parts of high density polyethylene with the average particle size D50 of 95 μm, 0.025 part of benzoyl peroxide were added. After the temperature of the reaction material was increased to 95° C. under the stirring rate of 85 rounds/min, 42 parts of chlorine gas was inlet, then the temperature was increased to 135° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet while increasing the temperature was 19 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The temperature was kept at 135-138° C. after reaching 135° C., and the rest 23 parts of chlorine gas was inlet at the rate of 23 parts/hour. The rubber powder with an elongation at break of 2380% was obtained after centrifugation and drying (sample 4).
The conversion of the reaction was 99.1%, the content of chlorine was 37.1%. The average particle size D50 of the powder was 210 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride compositions and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Example 5
(1) Preparation of Toughening Modifier
0.32 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is resistant to the erosion of chloric acid and is equipped with a zirconium-made stirring rake with both top and bottom ends fixed to the reactor, 0.05 parts of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 35 parts of high density polyethylene with the average particle size D50 of 95 μm, 0.03 part of benzoyl peroxide were added. After the temperature of the reaction material was increased to 100° C. under the stirring rate of 100 rounds/min, 42 parts of chlorine gas was inlet, then the temperature was increased to 135° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet while increasing the temperature was 19 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The temperature was kept at 135-138° C. after reaching 135° C., and the rest 23 parts of chlorine gas was inlet at the rate of 23 parts/hour. The rubber powder with an elongation at break of 2430% was obtained after centrifugation and drying (sample 5).
The conversion of the reaction was 98.9%, the content of chlorine was 37.0%. The average particle size D50 of the powder was 2301 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride compositions and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Example 6
(1) Preparation of Toughening Modifiers
0.34 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is resistant to the erosion of chloric acid and is equipped with a zirconium-made stirring rake with both top and bottom ends fixed to the reactor, 0.06 parts of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 35 parts of high density polyethylene with the average particle size D50 of 95 μm, 0.035 part of benzoyl peroxide were added. After the temperature of the reaction material was increased to 105° C. under the stirring rate of 125 rounds/min, 42 parts of chlorine gas was inlet, then the temperature was increased to 135° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet while increasing the temperature was 19 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The temperature was kept at 135-138° C. after reaching 135° C., and the rest 23 parts of chlorine gas was inlet at the rate of 23 parts/hour. The rubber powder with an elongation at break of 2490% was obtained after centrifugation and drying (sample 6).
The conversion of the reaction was 98.5%, the content of chlorine was 36.9%. The average particle size D50 of the powder was 250 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride compositions and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Example 7
(1) Preparation of Toughening Modifiers
0.35 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is resistant to the erosion of chloric acid and is equipped with a zirconium-made stirring rake with both top and bottom ends fixed to the reactor, 0.07 parts of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 35 parts of high density polyethylene with the average particle size D50 of 80 μm, 0.035 part of benzoyl peroxide were added. After the temperature of the reaction material was increased to 80° C. under the stirring rate of 120 rounds/min, 42 parts of chlorine gas was inlet, then the temperature was increased to 135° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet while increasing the temperature was 18 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The temperature was kept at 135-138° C. after reaching 135° C., and the rest 24 parts of chlorine gas was inlet at the rate of 24 parts/hour. The rubber powder with an elongation at break of 2530% was obtained after centrifugation and drying (sample 7).
The conversion of the reaction was 99.5%, the content of chlorine was 37.3%. The average particle size D50 of the powder was 180 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride compositions and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Example 8
(1) Preparation of Toughening Modifiers
0.45 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is resistant to the erosion of chloric acid and is equipped with a zirconium-made stirring rake with both top and bottom ends fixed to the reactor, 0.07 parts of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 35 parts of high density polyethylene with the average particle size D50 of 73 μm, 0.035 part of benzoyl peroxide were added. After the temperature of the reaction material was increased to 90° C. under the stirring rate of 125 rounds/min, 42 parts of chlorine gas was inlet, then the temperature was increased to 135° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet while increasing the temperature was 18 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The stirring rate was increased to 130 rounds/min and the temperature was kept at 137-140° C. after the temperature reaching 137° C., and the rest 24 parts of chlorine gas was inlet at the rate of 24 parts/hour. The rubber powder with an elongation at break of 2640% was obtained after centrifugation and drying (sample 8).
The conversion of the reaction was 99.5%, the content of chlorine was 37.3%. The average particle size D50 of the powder was 170 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride composition and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Example 9
(1) Preparation of Toughening Modifiers
0.30 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a 30 L reactor that is equipped with a stirring rake, 0.28 parts of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 25 parts of sample 8, 0.12 part of potassium persulfate were then added. After the temperature of the reaction material was increased to 80° C. under the stirring rate of 60 rounds/min, 2 parts of octyl acrylate and 1 part of butyl methacrylate were added then. The temperature was kept at 80-85° C. and was cooled to below 40° C. after 4 hours of reaction. The rubber powder with an elongation at break of 2725% was obtained after centrifugation and drying (sample 9).
The conversion of the reaction was 97.9%. The average particle size D50 of the powder was 330 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride compositions and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Example 10
(1) Preparation of Toughening Modifiers
0.45 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is resistant to the erosion of chloric acid and is equipped with a zirconium-made stirring rake with both top and bottom ends fixed to the reactor, 0.07 parts of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 35 parts of high density polyethylene with the average particle size D50 of 60 μm, 0.035 part of benzoyl peroxide were added. After the temperature of the reaction material was increased to 85° C. under the stirring rate of 130 rounds/min, 42 parts of chlorine gas was inlet, then the temperature was increased to 135° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet while increasing the temperature was 18 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The stirring rate was increased to 135 rounds/min and the temperature was kept at 137-140° C. after the temperature reaching 137° C. The rest 24 parts of chlorine gas was inlet at the rate of 24 parts/hour. The rubber powder with an elongation at break of 2930% was obtained after centrifugation and drying (sample 10).
The conversion of the reaction was 99.5%, the content of chlorine was 37.3%. The average particle size D50 of the powder was 160 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride compositions and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Comparative Example 1
(1) Preparation of Modifiers
0.20 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is resistant to the erosion of chloric acid and is equipped with a zirconium-made stirring rake with both top and bottom ends fixed to the reactor, 0.30 part of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 35 parts of high density polyethylene with the average particle size D50 of 1601 μm, 0.15 part of benzoyl peroxide were added. After the temperature of the reaction material was increased to 80° C. under the stirring rate of 90 rounds/min, 42 parts of chlorine gas was inlet, then the temperature was increased to 135° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet while increasing the temperature was 25 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The stirring rate was increased to 140 rounds/min and the temperature was kept at 135-137° C. after the temperature reaching 135° C., the rest 17 parts of chlorine gas was inlet at the rate of 16 parts/hour. The rubber powder with an elongation at break of 2030% was obtained after centrifugation and drying (comparative sample 1).
The conversion of the reaction was 99.0%, the content of chlorine was 37.1%. The average particle size D50 of the powder was 260 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride composition and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Comparative Example 2
(1) Preparation of Modifiers
0.35 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is resistant to the erosion of chloric acid and is equipped with a zirconium-made stirring rake with both top and bottom ends fixed to the reactor, 0.40 part of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 35 parts of high density polyethylene with the average particle size D50 of 180 μm, 0.15 part of benzoyl peroxide were added. After the temperature of the reaction material was increased to 80° C. under the stirring rate of 120 rounds/min, 42 parts of chlorine gas was inlet, then the temperature was increased to 137° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet while increasing the temperature was 25 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The stirring rate was increased to 125 rounds/min and the temperature was kept at 137-140° C. after the temperature reaching 137° C., the rest 17 parts of chlorine gas was inlet at the rate of 15 parts/hour. The rubber powder with an elongation at break of 1630% was obtained after centrifugation and drying (comparative sample 2).
The conversion of the reaction was 99.0%, the content of chlorine was 37.1%. The average particle size D50 of the powder was 280 μm.
(2) Preparation of Polyvinyl Chloride Compositions and Polyvinyl Chloride Sheet Products
The preparation method of polyvinyl chloride compositions and polyvinyl chloride sheet products is the same as that of example 1. The elongation at break was measured; the results of the experiment can be seen in table 1.
Comparative Example 3
Preparation of Modifiers
0.35 part of water-soluble methyl methacrylate-acrylic acid copolymer was added as a dispersing agent to a reactor that is equipped with a stirring rake with one end fixed to the reactor, 0.40 part of polyoxyethylene lauryl ether was added as an emulsifying agent, then water was added, the total amount of water used and the amount of all the auxiliary raw materials were 250 parts. Then 30 parts of high density polyethylene with the average particle size D50 of 80 μm, 0.15 part of benzoyl peroxide were added. After the temperature of the reaction material was increased to 80° C. under the stirring rate of 120 rounds/min, 35 parts of chlorine gas was inlet, then the temperature was increased to 137° C. while inletting chlorine gas. The time for increasing the temperature was 1 hour, the amount of the chlorine gas inlet while increasing the temperature was 15 parts, and the temperature increasing and the chlorine gas inlet were carried out simultaneously. The stirring rate was increased to 140 rounds/min and the temperature was kept at 137-140° C. after the temperature reaching 137° C., the rest 20 parts of chlorine gas was inlet at the rate of 20 parts/hour. When the amount of the chlorine gas inlet was 6 parts at the temperature above 137V, the viscosity of the reaction liquid was increased, the stirring rake started to sway vibrately and so did the rector, the pressure inside the reactor started to increase quickly, the rate of reaction of chlorination decreased dramatically. In order to prevent the occurrence of safety accident, the inlet of chlorine gas was stopped and the temperature was decreased quickly to stop the reaction. The reaction was failed.
TABLE 1
Elongation
at break of polyvinyl
Elongation
chloride composition
at break of rubber
Number
sheet products (%)
powders (%)
Example 1
243
2230
Example 2
249
2260
Example 3
256
2320
Example 4
260
2380
Example 5
273
2430
Example 6
278
2490
Example 7
282
2530
Example 8
285
2640
Example 9
292
2725
Example 10
301
2930
Comparative example 1
232
2030
Comparative example 2
196
1630
From table 1, it can be seen that the larger the elongations at break of the toughening modifiers are, the larger the elongations at break of the polyvinyl chloride composition sheet products are, and thus the better the toughnesses of the polyvinyl chloride composition products are.
Examples 11-14
Except the amount of use of the toughening modifier (sample 7) in the polyvinyl chloride composition were changed, the rest of the steps and the conditions are the same of that of example 7. In examples 11, 12, 13 and 14, the amount of use of sample 7 were 6 parts, 7 parts, 9 parts and 11 parts respectively. The experiments results can be seen in table 2.
Comparative Examples 4-5
Except the amount of use of the toughening modifier (sample 7) in the polyvinyl chloride composition were changed, the rest of the steps and the conditions are the same of that of example 7. In the comparative examples 4 and 5, the amounts of use of sample 7 were 1 part, 1.8 parts respectively. The experiments results can be seen in table 2.
Comparative Example 6
Except the amount of use of the toughening modifier (sample 7) in the polyvinyl chloride composition were changed, the rest of the steps and the conditions are the same of that of example 7. In the comparative examples 7, the amount of use of sample 7 was 28 parts. Polyvinyl chloride composition cannot be molded by extrusion of extruding machine because of the poor processability of the composition. The experiments results can be seen in table 2.
TABLE 2
Sample 7
Elongations at break of polyvinyl
(Parts by weight)
composition sheet products (%)
Example 11
6
233
Example 12
7
271
Example 13
9
305
Example 14
11
313
Comparative
1
110
example 4
Comparative
1.8
116
example 5
Comparative
28
—
example 6
It can be seen from table 2 that the higher the amounts of use of the toughening modifiers, the larger the elongations at break of the polyvinyl chloride compositions are. However, the elongations at break of the polyvinyl chloride compositions are very low when the amounts of use of the toughening modifiers are less than 2 parts. When the amounts of use of the toughening modifiers are larger than 16 parts, the polyvinyl chloride compositions can hardly be molded by processing. | The present invention discloses a polyvinyl chloride modifier, composition and a preparation method thereof. The composition comprises the following components by parts by weight: (a) polyvinyl chloride resin of 100 parts, and (b) a toughening modifier of 2-16 parts, the toughening modifier being rubber powder whose an elongation at break is greater than 2201% and which contains weight percentage of chlorine of 5-45 wt %. The elongation at break of the polyvinyl chloride composition of the present invention is greatly improved, and the defect of low elongations at break of polyvinyl chloride product is substantially solved accordingly, therefore, the application scope of polyvinyl chloride surely will be greatly widened. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 08/200,476, filed Feb. 23, 1994, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a method of, and a patella clamp and reamer with an adjustable stop for, in situ preparation of a patella.
During certain forms of surgery involving the knee, such as the implantation of a knee joint prosthesis, the natural patella is resected for subsequent implantation of an artificial patella component. During such a resection, various parameters must be considered in determining the desired depth of the resection. For example, the surgeon must consider the thickness of the natural patella as well as the thickness of the artificial patella components which will be implanted. In addition, the artificial patella component is typically available in different diameters so as to give the surgeon flexibility in operating on natural patellas of different sizes. However, an increase in the diameter of the artificial patella component normally results in a corresponding increase in the thickness of the artificial patella component. It is therefore often difficult for a surgeon to easily determine the depth to which a natural patella must be resected when having to consider all of these factors.
Once the surgeon has determined how much the natural patella should be resected, the patella is clamped so as to hold the patella in the fixed position. Various devices have been developed which allow the surgeon to hold the patella stationary. These devices typically involve hand operated scissors and vise-grip mechanisms. However, these devices suffer from the fact that the surgeon must maintain a clamping pressure on the patella. This application of clamping pressure may not be uniform during the resection of the patella, and possibly result in the patella being malpositioned. Accordingly, in some of the known constructions, gimbals are necessary in the jaws of such instruments to accurately position the patella during the resection procedure. Finally, some of these devices, such as the four-bar clamp which is available from Biomet, are large and bulky and therefore difficult to use and do not provide a relatively high degree of tactile feedback.
In addition, presently available instruments move a guide bushing into position against the posterior surface of the patella to clamp the patella and guide the reamer. This obscures the view of the patella such that the surgeon cannot see the patella during the resection process. This arrangement also tends to generate wear debris because the cutting blade assembly tends to contact the guide bushing.
SUMMARY OF THE INVENTION
The present invention overcomes the deficiencies in the prior art by providing an improved method and instrument for use in the implantation of an artificial patella component.
The instrument comprises a hand manipulated patella clamp including a guide head which forms part of an adjustable stop and a reaming device for performing either a resurfacing procedure or an insetting procedure for preparing a surface of a patella for a prosthetic patella implant. The patella clamp includes a pair of generally parallel upper and lower arms, each arm including a handle at one end and a jaw at the other end. The patella clamp further includes a pair of guide posts which connect the upper and lower arms together in generally parallel relation and guide the arms for parallel movement towards one another. Finally, the patella clamp includes an incrementally adjustable arrangement for locking and releasing the jaw members.
The reaming device includes an elongated shaft mountable for rotation in the guide head, a cutter blade removably connected to the shaft by means of a coupling, and a depth adjustment head connected to the shaft. The depth adjustment head is adapted to engage the guide head to accurately position the cutter blade relative to the anterior portion of the patella. The shaft has an upper end portion adapted to be driven by a surgical drill so as to cause rotation of the cutting blade assembly.
The method for the resection of a patella comprises measuring the thickness of the natural patella and then adjusting the position of the depth adjustment head relative to the reamer shaft at least partially in response to the thickness of the patella. The reamer shaft is then rotated and moved in a direction toward the patella until the depth adjustment head engages the patella clamp to prevent further movement of the reamer shaft in the direction toward the patella.
An advantage of the present invention is provision of a hand manipulated clamp which maintains two jaw members in parallel relation thereby eliminating gimbals for positioning the patella.
Another advantage of the present invention is to provide a method and apparatus for preparing a natural patella to receive an artificial patella implant which is calibrated to provide a desired degree of resection based upon the measurement of the thickness of the natural patella and the intercondylar thickness of the femur.
A further advantage of the present invention is that the patella clamp moves the reamer guide mechanism away from the posterior surface of the patella thereby enhancing the view of the patella surface being resected.
Another advantage of the present invention is that the jaws of the patella clamp maintain a uniform clamping pressure on the patella during the reaming operation and provide tactile feedback.
Yet another advantage of the present invention is the presence of a bearing arrangement utilizing a sleeve which is displaced from the patella for supporting and guiding the reamer shaft which enables close rotating tolerances to be maintained without binding.
A further advantage of the present invention is to provide a method and apparatus for preparing a natural patella to receive an artificial patella implant which is relatively easy to use and is able to firmly grip the natural patella.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional advantages and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a top elevational view of a patella clamp and reamer according to the teachings of a preferred embodiment of the present invention;
FIG. 2 is a side elevational view of the patella clamp and reamer shown in FIG. 1 with part of the reamer and clamp shown in cross-section according to the teachings of the preferred embodiment of the present invention;
FIG. 3 is an exploded perspective view of the patella clamp and reamer shown in FIG. 1 according to the teachings of the preferred embodiment of the present invention;
FIG. 4 is an exploded perspective view of the cutting blade assembly shown in FIG. 3 according to the teachings of the preferred embodiment of the present invention;
FIG. 4A is a perspective view of an optional blade member having both a diameter and a height less than that of the blade member of FIG. 4;
FIG. 5 is an elevational cross-sectional view of a cutting blade assembly shown in FIG. 4 according to the teachings of the preferred embodiment of the present invention;
FIG. 6 is a side view of the distal end of a resected femur and selected resected portions shown in spaced-apart relation from the femur;
FIG. 7 is a perspective view of the resected femur of FIG. 6 showing the resected distal femoral portion in spaced-apart relation from the femur;
FIG. 8 is a top view of the resected anterior chamfer portion of the resected femur of FIG. 6;
FIG. 9 is a sectional view of the resected portion of FIG. 8;
FIG. 10 is an elevational view of the patella clamp and reamer shown in FIG. 1 engaging the anterior surface of a patella according to the teachings of the preferred embodiment of the present invention;
FIG. 11 is an elevational view of the patella clamp and reamer shown in FIG. 1 engaging the posterior surface of the patella and in clamped relation with the patella according to the teachings of the preferred embodiment of the present invention; and
FIG. 12 is an elevational view of the cutting blade assembly being operatively positioned against the posterior surface of the patella according to the teachings of the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
It should be understood that while this invention is described in connection with a particular example, the scope of the invention need not be so limited. Rather, those skilled in the art will appreciate that the following teachings can be used in much wider variation of applications than the example specifically mentioned herein.
Referring now to FIGS. 1-3, there is shown a surgical apparatus which is generally designated by the numeral 10. The surgical apparatus 10 is used for performing either a total resurfacing procedure or an insetting procedure on a human patella prior to receiving an artificial patella component of a knee joint prosthesis. The surgical apparatus 10 includes a patella clamp 12 and a reaming device 14. The patella clamp 12 is used to engage the natural patella in a secure fashion. The reaming device 14 is used to resect the natural patella while the natural patella is being held by the patella clamp 12.
The patella clamp 12 will now be described in greater detail. The patella clamp 12 includes lower and upper arms 16 and 18 in the form of generally flat plate-like members. The lower and upper arms 16 and 18 include a handle portion 20 and 22 at one of its ends and a jaw member 24 and 26 at the other of its ends, respectively. The patella clamp 12 further includes a pair of axial guide posts 28 for guiding the lower and upper arms 16 and 18, as well as a pair of coil springs 30 and a pair of cylindrical guide housings 32. Each of the axial guide posts 28 are encircled by one of the coil springs 30 such that the ends of each of the coil springs 30 operate against the surfaces 20a and 22b of the handle portions 20 and 22 which serve to bias the lower and upper arms 16 and 18 away from one another.
The guide posts 28 are adapted to reciprocate relative to a plurality of openings 21 in the lower handle portion 20. The guide posts 28 include a base 28a that is connected to the lower surface 22b of the upper handle portion 22 and a free end portion 28b. The guide housings 32 extends perpendicularly from the lower surface 20b of the lower handle 20 and each has an inner bore that receives the free end portion 28b and guides the respective guide post 28 for reciprocation therewithin. The guide post 28 forms a bearing member and is comprised of a material which will enhance smooth reciprocation in its guide housing 32 and obviate frictional forces from causing the lower and upper arms 16 and 18 to bind during a clamping motion. The guide posts 28 are preferably made from stainless steel while the guide housing 32 is preferably made from a composite material such as Frelon®. However, other suitable materials may be used.
The lower and upper arms 16 and 18 and the guide posts 28 form a generally rectangularly shaped assembly. In this regard, the guide posts 28 are parallel to one another and generally perpendicular to the handle portions 20 and 22. The lower and upper arms 16 and 18 are disposed in generally parallel relation and the jaw members 24 and 26 are constrained by the guide posts 28 for parallel movement towards and away from one another. This arrangement assures accurate positioning of the jaw members 24 and 26 and uniform application of clamping forces on the patella.
The lower jaw member 24 includes a slightly concave surface 34 to support the patella and is provided with one or more spikes 36 to enter and thereby grip the anterior surface of the patella. The upper jaw member 26 includes a cylindrical opening 38 and a cylindrical collar 40 arranged generally concentrically relative to a vertical axis shown at "A". Preferably, the collar 40 has an engagement face 42 which is contoured to provide a substantially continuous and uniform engagement with the posterior surface of the patella. According to a preferred embodiment, the patella engagement face 42 is formed to include V-shaped teeth for gripping the patella and ensuring that the patella does not shift during the resection.
The lower and upper arms 16 and 18 of the patella clamp 12 are adapted to be locked in a predetermined spaced relation with one another by a ratchet-type locking arrangement operating in conjunction with the upper handle portion 22. In this regard, the patella clamp 12 further comprises an L-shaped member 44 which has a lower end portion secured to the lower handle portion 20, such as by a fastener 46, a central body portion extending through an opening 48 in the upper handle portion 22 and having ratchet teeth 52 formed thereon, and a guide head 50 positioned above the upper surface 22a of the upper handle portion 22. The guide head 50 includes lower and upper end faces 54 and 56 and a cylindrical guide bore 58 that extends between the lower and upper end faces 54 and 56. The axis of the guide bore 58 and the axis "A" are generally coaxially aligned and perpendicular to the handle portions 20 and 22. According to this invention, the surface of the guide bore 58 is formed from a material having a low coefficient of friction. While metal is suitable for this purpose, the surface of the guide bore 58 may include a sleeve of Ultem® though other suitable materials may be used.
Supported on the upper surface 22a of the upper handle portion 22 is an elongated locking bar 60, a latch spring 62, and an elongated open-ended cover 64 of U-shaped cross-section that encloses the forward end of the locking bar 60 and the latch spring 62. The locking bar 60 is provided with a latch spring slot 66, an axial guide slot 67, and, at its forward end, a locking tooth 68 to interengage with the ratchet teeth 52. Threaded fasteners 70A and 70B extend through the cover 64 and into the upper handle portion 22, with the fastener 70A passing through the guide slot 67 to secure the cover 64 and the locking bar 60 to the handle portion 22. The sidewalls of the cover 64, the guide slot 67, and the fastener 70A operate to guide the locking tooth 68 of the locking bar 60 towards the ratchet teeth 52. The latch spring slot 66 includes a forward end 71. The latch spring 62 is captivated inside the cover between the fastener 70B and the forward end 71 of the latch spring slot 66. The latch spring 62 normally biases the locking tooth 68 into engagement with the ratchet teeth 52, the locking tooth 68 and ratchet teeth 52 being configured to permit the handle portions 20 and 22 to incrementally advance towards one another and the jaw members 24 and 26 into clamped engagement with the patella but operate to normally prevent reverse movement.
To release the locking tooth 68 from engagement with the ratchet teeth 52, a T-bar handle 72 is provided on the locking bar 60. The T-bar handle 72 is used to retract the locking bar 60 from the ratchet teeth 52 so as to permit movement between the lower handle portion 20 and the upper handle portion 22. This is done when it is desirable to release the patella from the jaw members 24 and 26. It will therefore be appreciated that the patella clamp 12 is configured to allow the surgeon to maintain a grip on the handle portions 20 and 22, to increase the clamping pressure on the patella, and use a finger to engage the T-bar to pull the locking bar rearwardly and cause the locking tooth 68 to be disengaged from the ratchet teeth 52.
The reaming device 14 will now be described in greater detail. The reaming device 14 includes a stepped axial reamer shaft 74, a depth adjustment head 76, and a cutting blade assembly 78 for reaming the patella. The cutting blade assembly 78 is used to ream the surface of the patella. The depth adjustment head 76 and the reamer shaft 74 are adapted to be positioned relative to one another, and the adjustment head 76 relative to the guide head 50, to accurately position the cutting blade assembly 78 relative to the patella when the patella is clamped in position by the jaw members 24 and 26. The reamer shaft 74 has an upper end 80 adapted to be engaged by a surgical drill (not shown) which is used to rotate the reamer shaft 74, a threaded upper end portion 82 adapted to engage the depth adjustment head 76, a central portion 84 adapted to rotate within the guide bore 58 of the guide head 50, and a threaded portion 86.
The depth adjustment head 76 has upper and lower end faces 90 and 92 and an axial bore 94 extending therethrough between the end faces 90 and 92 for receiving the threaded upper end portion 82 of the reamer shaft 74. The cross-section of the axial bore 94 of the depth adjustment head 76 is substantially the same as that of the upper end portion 82 of the reamer shaft 74 but dimensioned to provide a clearance fit to permit the reamer shaft 74 to move axially therewithin. The lower end face 92 of the adjustment head 76 is adapted to seat against the upper end face 56 of the guide head 50 of the patella clamp 12 so that the end faces 56 and 92 cooperate to form an adjustable stop which limits downward advance of the reamer shaft 74 and the cutting blade assembly 78. Importantly, the stop prevents the surgeon from inadvertently removing an excessive amount of material from the natural patella.
The depth adjustment head 76 also includes a locking and release arrangement whereby the depth adjustment head 76 may easily be locked in any desired position relative to the threaded upper end portion 82 of the reamer shaft 74 and/or released from threadable engagement therewith. The locking and release arrangement includes a stepped radial bore 96 in the depth adjustment head 76 that intersects and extends across the axial bore 94, an axial lock pin 98 having opposite axial ends 98a and 98b and slidably fitted in the radial bore 96, and a lock spring 100 disposed at the bottom of the radial bore 96 to normally force the lock pin 98 radially outwardly from the radial bore 96. The lock pin 98 is formed to include a transverse lock bore 102 of elliptical cross-section sized to pass the reamer shaft 74 with the long and short dimensions of the circular cross-section having a flat 104 respectively extending in the direction of and transverse to the radial bore 96. The long dimension of the lock bore 102 constitutes a first bore wall 102a facing in a direction radially outwardly of the radial bore 96 and a second bore wall 102b facing in a direction radially inwardly of the radial bore 96. Importantly, the bore wall 102a is formed with a lip or thread which is normally biased by the lock spring 100 into locked engagement with the thread on the upper end portion 82 of the reamer shaft 74.
To incrementally adjust the position of the depth adjustment head 76 relative to the reamer shaft 74, or release the engagement, the surgeon applies an inwardly directed force against the end 98b of the lock pin 98 thereby forcing the end 98a further inward in the radial bore 96. As a result, the thread formed on the wall 102a of the Lock pin 98 is moved from engagement with the thread on the reamer shaft 74 and the reamer shaft 74 is released for movement in the axial bore 94 relative to the depth adjustment head 76. Upon removal of the force against the end 98b of the lock pin 98, the lock spring 100 forces the lock pin 98 back into engagement with the thread on the reamer shaft 74.
During rotation of the reamer shaft 74, it is preferable that the depth adjustment head 76 does not rotate relative to the upper end portion 82 of the reamer shaft 74 thereby causing the preset spacing between the lower end face 92 of the depth adjustment head 76 and the patella to change. Accordingly, the upper end portion 82 of the reamer shaft 74 has a flat 104 formed with measurement settings 105 thereon and the axial bore 94 is formed to include a flat 106. The flats 104 and 106 operate to key the measurement settings 105 relative to the lock pin 98 and prevent relative rotation between the depth adjustment head 76 and the reamer shaft 74. The measurement settings 105 on the reamer shaft 74 correlate the distance between the upper end face 56 of the guide head 50 and the lower jaw member 24 in terms of the amount of the natural patella that will be left after resection. In particular, the measurement settings 105 can be related to the thicknesses of the natural patella before resection as well as the intercondylar thickness of the femur before or after resection as shown below in FIGS. 6-9 and as described with respect thereto.
The location of the measurement settings 105 on the reamer shaft 74 are selected to correspond to the thickness of the natural patella as measured by the surgeon. This enables the surgeon to select the proper measurement setting 105 by simply measuring the thickness of the patella. For example, if the surgeon determines that the thickness of the natural patella is 23 mm., the surgeon would adjust the depth adjustment head 76 to the measurement setting 105 identified as 23 mm. The length of the reamer shaft 74, as well as the height of the cutting blade assembly 78, is such that the natural patella is reamed to the desired depth once the depth stop head 76 engages the upper end face 56 of the guide head 50 such that the proper amount of bone remains after resection. While the thickness of artificial patella components vary depending on their diameter, the height of the cutting blade assembly 78 is selected to be greater for a thicker patellar implant and is thinner for a thinner patellar implant. For example, if the natural patella is determined to be 23 mm in thickness and a medium diameter patellar implant is used which has thickness of 9 mm, then placing the depth adjustment head 76 at 23 mm will leave 14 mm of bone remaining in the cavity formed in the natural patella. However, if a large diameter patellar implant is selected which has a thickness of 10 mm, then placing the depth adjustment head 76 at 23 mm will leave 13 mm of bone remaining in the cavity formed in the natural patella.
It has also been determined that it is desirable to adjust the depth of reaming in response to the intercondylar thickness of the femoral component of a knee joint prosthesis. This is because selecting the depth of the resection of the patella based solely on the thickness of the patella does not place the remaining natural patella, with the artificial patella component attached, at the same anatomical position as before surgery. In particular, because the resected intercondylar thickness of the femur is not the same as the intercondylar thickness of the femoral component, the quadriceps tendon often is not placed at the same location (typically increasing forces at 45° of flexion) after implantation as before the knee joint is replaced. Accordingly, to replicate the kinematics of the knee prior to joint replacement, it is desirable to adjust the depth to which the patellar implant is placed into the natural patella so that the quadriceps tendon will be placed in the same anatomical position after joint replacement as it was before joint replacement.
To adjust the depth of reaming to accommodate for the intercondylar thickness of the femoral component, the location of measurement settings 105 on the reamer shaft 74 may be determined as follows:
Equation (1):
Location of measurement settings=PT+ST+(IT femur -IT implant ) 105 on reamer shaft 74
where:
PT=thickness of natural patella (in mm.)
ST=thickness of saw blade used in anterior femoral resection (in mm.)
IT femur =resected intercondylar thickness of the femur (in mm.)
IT implant =intercondylar thickness of implant femoral component (in mm.)
Under certain assumptions, this equation can be simplified such that the location of the measurement settings 105 on the reamer shaft 74 depend only on the thickness of the natural patella and the intercondylar thickness of the femur. These assumptions include assuming that the intercondylar thickness of the femoral component of the knee joint prosthesis is constant for all sizes of implants (at approximately 3.5 mm) which is generally true for the majority of the knee joint prostheses available from Biomet. In addition, an assumption can be made that the thickness of the saw blade used in the anterior resection of the femur is about 1.5 mm. This is because the cutting blocks which are typically used to perform this resection, such as those available from Biomet, specify a blade thickness of 1.5 mm.
If these assumptions are made, the location of the measurement settings 105 on the reamer shaft 74 are determined by the following equation:
Equation (2):
Location of measurement settings PT+IT femur -2 mm 105 on reamer shaft 74
where:
PT=thickness of natural patella (in mm.)
IT femur =resected intercondylar thickness of the femur (in mm.)
With this simplified equation, the surgeon can simply adjust the depth adjustment head 76 to a position on the reamer shaft 74 such that the measurement setting 105 chosen is equal to the thickness of the natural patella plus the intercondylar thickness of the femoral component of the knee joint prosthesis less 2 mm. If either of the above assumptions are not accurate for the particular implant being used, then Equation (1) should be applied.
The cutting blade assembly 78 will now be described in greater detail with reference to FIGS. 4, 4A and 5. The cutting blade assembly 78 includes a blade member 108 and a coupling member 110. The coupling member 110 is used for securing the blade member 108 to the reamer shaft 74 by engaging the threaded portion 86 of the reamer shaft 74 with an internally threaded bore 112. The coupling member 110 includes a drill member 114 which is secured to the lower end of the coupling member 110 which is used to drill the natural patella, as well as a fixed pin member 116 and a movable pin member 118 which are used to removably attach the blade member 108 to the coupling member 110. The movable pin member 118 engages an aperture 120 in the blade member 108 while the fixed pin member 116 engages a slot 121 on the blade member 108. The coupling member 110 also includes a spring 122 which is used to bias the movable pin member 118 into engagement with the aperture 120, and a pin driver 123 which is operable to cause displacement of the movable pin member 118 so as to allow the blade member 108 to be removed from the coupling member 110. Finally, the blade member 108 has a plurality of cutting flanges 124 which are used to remove bone from the patella and to pass bone shavings into a chamber 126 formed between the blade member 108 and the coupling member 110.
As discussed above, the thickness of the cutting blade assembly 78 is selected to be different for different diameters of patellar implants. To accomplish this, the thickness of the blade member 108 varies with the diameter of the blade member 108. In particular, a blade member 108 having a greater diameter also has a greater height, while a blade member 108' (shown in FIG. 4A) having a smaller diameter is smaller in height. This permits the surgeon to select the proper measurement setting 105 by measuring only the thickness of the natural patella, without having to adjust the depth of reaming for varying thicknesses of patellar implants.
As mentioned above, the measurement settings 105 can be related to the intercondylar thickness of a selected portion of the femur as well as the thickness of the natural patella before resection. The intercondylar thickness measurement is based upon a selected portion of a resected portion of the femur or the portion about to be resected.
FIGS. 6 through 9 illustrate the femur and resected portions. One of these resected portions of the femoral resection forms the basis for the intercondylar thickness measurement. In particular, FIGS. 6 and 7 illustrate views of the distal end of a femur 128 and various resected portions. Specifically, FIG. 6 illustrates a side view of the distal end of the femur 128 showing a resected distal femoral portion 130, a resected anterior femoral condyle portion 132, and a resected anterior chamfer portion 134. As is known to those skilled in the art, additional cuts are made to the distal end of the femur 128 in preparation for receiving a prosthesis (not shown). The resected portions include a posterior femoral condyle portion and a posterior chamfer portion, neither of these portions being shown resected for the sake of simplicity.
FIG. 7 illustrates the distal end of the femur 128 partially resected. Specifically, both the distal femoral resection and the anterior femoral condyle resection have been made. The resected distal femoral condyle portion 130 is shown in spaced-apart relation from the femur 128. The resected anterior femoral portion 132 (shown in FIG. 6) is not illustrated in FIG. 7. A dotted line "ACR" identifies the line of resection for the anterior chamfer resection. Once this latter resection is made, the resected anterior chamfer portion 134 is formed.
The resected anterior chamfer portion 134, as illustrated in FIG. 6, is generally triangular in cross-section. However, as illustrated in FIG. 8, which is a top view of the resected anterior chamfer portion 134, the triangular configuration is not continuous but is interrupted by a recessed area 136 (also shown in FIG. 7). The recessed area 136 is actually defined by the upper surface of an intercondylar bridge or mass 137. The recessed area 136 includes patellar cartilage. The recessed area 136 also forms a first point for measurement of the intercondylar bone thickness, as illustrated in FIG. 9. The other point for measurement is the resected underside 138 of the resected anterior chamfer portion 134, which is also illustrated in FIG. 9. The width between the recessed area 136 and the resected underside 138 of the portion 134 is the intercondylar bone thickness, illustrated in FIG. 9 as "T--T" or the area between arrows "I-B-T". FIG. 9 also illustrates another measured width, which is the blade thickness, which is defined as "BT" or the area between the arrows "Bl-T".
The intercondylar bone thickness or T--T and the blade thickness B-T provide useful data in determining the measurement settings.
The method of using the surgical instrument 10 will now be described with reference to FIGS. 10-12. The anterior contour cuts of the femur are resected prior to receiving a commercially available implant (not shown). The surgeon then preferably estimates the intercondylar thickness of the intercondylar mass 137 of the resected anterior chamfer portion 134 by measuring the thickness T--T of the portion 134 as a result of the anterior chamfer cut illustrated in FIGS. 6 and 7. After the above measurements have been made, the surgeon grips the handle portions 20 and 22 and position the concave surface 34 of the lower jaw member 24 under the anterior surface of a patella, illustrated as 140. The handle portions 20 and 22 are then driven towards one another thereby causing the upper jaw member 26 to be driven downwardly against the force of the springs 30 so as to cause the patella 140 to be gripped between the two jaw members 24 and 26.
Thereafter, the cutting blade assembly 78 is fitted to the threaded portion 86 of the reamer shaft 74. The depth adjustment head 76 is positioned relative to the reamer shaft 74, and relative to the measurement indicia, depending on how much material is to remain after the resection. In particular, the depth adjustment head 76 is adjusted to equal the thickness of the natural patella 140 plus the intercondylar thickness T--T of the resected anterior chamfer portion 134 less 2 mm. If the intercondylar thickness T--T is not equal to 3.5 mm of the thickness or the saw blade is not equal to 1.5 mm, the general formula described in Equation (1) may be used. The cutting blade assembly 78 is then attached to the reamer shaft 74 by causing engagement between the threaded portion 86 with the internally threaded bore 112. The upper end 80 of the reamer shaft 74 is then connected to a surgical drill and the reamer shaft 74 is rotated. The reamer shaft 74 is moved downward toward the patella 140 thereby causing the cutting blade assembly 78 to progressively engage and remove material from the patella 140. This downward movement of the reamer shaft 74 continues until the lower end face 92 of the depth adjustment head 76 engages the upper end face 56 of the guide head 50, whereupon the predetermined amount of bone material will be left after the resection from the patella 140. Thereafter, the cutting blade assembly 78 is removed from the reamer shaft 74 and then the patella clamp 12 is released from gripping engagement with the patella 140.
While the above detailed description describes the preferred embodiments of the present invention, it should be understood that the present invention is susceptible to modification, variation and alteration without deviating from the subjoined claims. | A method and surgical instrument is provided for the in situ clamping engagement and reaming of the human patella bone in preparation for the installation of a patellar button prosthesis, the clamp including a rectangular frame wherein a pair of handles are mounted for parallel movement whereby to move their respective jaws into clamped engagement with the opposite faces of the patella, and a guide head defining a fixed stop; and a reaming device including a reamer shaft disposed for rotation relative to the guide head, a depth adjustment head connected to the shaft and adapted to abut the fixed stop, and a reamer blade mounted to the shaft. The shaft is provided with indicia to indicate the thickness of the patella that will remain after the resection. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of and priority to U.S. Provisional Patent Application No. 60/783,108 filed Mar. 14, 2006 the technical disclosures of which are hereby incorporated herein by reference.
TECHNICAL FIELD OF INVENTION
The present invention relates generally to a continuously variable transmission (CVT) and specifically to a system and method for providing an automated adjustment to a CVT.
BACKGROUND OF THE INVENTION
A transmission is any mechanical linkage that converts an input torque to an output torque. It usually involves a series of gears that have differing diameters, allowing a first gear at a first rotation rate to link to a second gear rotating at a second rate. The most common application for transmissions is in a vehicle. For example, a car may have an automatic transmission or a manual transmission. A bicycle has a simple transmission that links the pedals to the hub of the rear wheel.
Transmissions allow an input force to be converted into a more useful and appropriate output. However, by using gears and linkages, a typical transmission may only have 4 or 5 ratios available. For example, a four speed automatic transmission in a car has only 4 sets of output gears to couple to the engine's input. A ten speed bike has only ten ratios of input to output. A need exists for a transmission that is not limited by the number of gears. Yet, to place a larger number of gears into a transmission increases its costs and weight and space requirements.
A continuously variable transmission (CVT) is a transmission that eliminates the need for a specified number of gears. Instead it allows an almost limitless number of input to output ratios. This is a benefit because it allows an output to be achieved (i.e. the speed of a vehicle) at an optimal input (i.e. the rpm of the engine). For example, an engine might be most efficient at 1800 rpm. In other words, the peak torque output for the engine might be achieved at this engine rpm, or perhaps the highest fuel economy. Consequently, it may be desirable to run at a specified RPM for an economy mode or a power mode. Yet, in third gear, the car might be going faster at 1800 ipm than the driver desires. A continuously variable transmission would allow an intermediate ratio to be achieved that allowed the optimal input to achieve the desired output.
CVT transmissions have a variator for continuously variable adjustment of the ratio. A customary structure is a belt drive variator having two pairs of beveled pulleys and rotating a torque-transmitter element therein, such as a pushing linked band or a chain. The beveled pulleys are loaded with pressure from the transmission oil pump in order, on one hand, to actuate the ratio adjustment and, on the other, to ensure a contact pressure needed for transmission of the torque upon the belt drive element. Another usual structure is a swash plate variator in semi-toroidal or fully toroidal design.
Examples of CVTs are exemplified by U.S. Pat. Nos. 6,419,608 and 7,011,600 assigned to Fallbrook Technologies of San Diego, Calif., the contents of which are hereby incorporated by reference. In each of those applications the axial movement of a rod or an axial force (as indicated by numeral 11 in each reference) is used to vary the input-to-output ratio of such transmissions.
FIG. 1 is a prior art schematic representation depicting the operation of manually controlled CVT or variator in a light electric vehicle, such as a scooter. As shown in FIG. 1 , a manual push button control box 101 has buttons corresponding to a signal output 108 of 0% 102 , 25% 103 , 50% 104 , 75% 105 , and 100% 106 sent to a microprocessor 112 . The microprocessor output can be shown on a display 150 . The microprocessor 112 interfaces with a motor control board 114 which receives power from a battery pack 118 .
A servo motor 120 engages a 90-degree gearbox 122 which provides an axial force 130 to a variator (CVT) 132 in contact with the rear wheel 134 . The rear wheel 134 is powered by a chain 136 or other equivalent means connected to a drive motor 140 (e.g., Briggs & Stratton ETEK).
The speed of the drive motor 140 is regulated by a current sent by a motor control device 144 . The motor control device 144 is regulated by a throttle 146 and is powered by the battery 118 .
While a user of the electric vehicle can manually shift gears using the push button control, it would be desirable to have an automatic shifting transmission to permit an electric scooter to operate in a power mode or an economy mode. Consequently, a need exists to automatically adjust the input to output ratio based upon one or more input variables.
SUMMARY OF THE INVENTION
The present invention provides a system and method for automatically adjusting a continuously variable transmission (CVT) in a motorized vehicle, such as a battery powered scooter. A microprocessor processor in the vehicle receives data about the operating status of the vehicle from a plurality. Examples of vehicle data include vehicle speed, motor speed, throttle position, current draw from a battery, battery level, CVT setting, control settings of a motor control device, wind direction, wind speed, and tire pressure. A servo motor is in mechanical communication with the CVT and provides an axial force to adjust the CVT. The microprocessor uses lookup tables of optimal set points for vehicle data to instruct the servo motor to adjust the transmission ratio of the CVT according to the vehicle data provided by the sensors.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a prior art schematic representation depicting the operation of a manually controlled variator in a light electric vehicle;
FIG. 2 is a schematic representation depicting the operation of automatically controlled variator in a light electric vehicle in accordance with one embodiment of the present invention;
FIG. 3A is a schematic representation of the automatic operation of the shifter in accordance with one embodiment of the present invention;
FIG. 3B is a schematic representation of the 90° gearbox in accordance with one embodiment of the present invention;
FIG. 4A is a schematic representation of a linear actuator in accordance with an alternative embodiment of the present invention;
FIG. 4B is a schematic representation of a servo motor mounted on the rear wheel in accordance with an alternate embodiment of the present invention;
FIG. 4C is a schematic representation of an alternate servo motor design in accordance with another embodiment of the present invention; and
FIG. 4D is a schematic representation of the servo motor in communication with a hub that contains the variator in accordance with another alternate embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 2 is a schematic representation depicting the operation of an automatically controlled variator in a light electric vehicle in accordance with one embodiment of the present invention. Instead of a push button control box 101 to manually control the transmission ratio of a CVT as shown in FIG. 1 , the present invention uses one or more automatically-generated variables to automatically adjust the variator (CVT).
The amount of current being drawn from the motor control device 144 , as provided by sensor 244 , comprises an automatically generated variable that can be used as an input signal to the microprocessor 112 . Motor controllers such as those available from Altrax of Grants Pass, OR can be used. Motor current draw is a function of throttle position and the state of the vehicle. For example:
Full throttle at 0 mph=full current draw Full throttle at 35 mph down a hill=low current draw
Another automatically generated variable supplied to the microprocessor 112 is the speed of the scooter, which is provided by a speed sensor 236 mounted on the front wheel 136 . In the preferred embodiment, multiple magnets (e.g., 16) are mounted around the rim of the front wheel 136 . All of the magnet poles are arranged in the same direction. The front wheel sensor 236 is mounted in a bracket from the wheel axel and wired into microprocessor 112 . The microprocessor 112 counts a pulse when a magnet passes the sensor 236 . The number of pulses in a given time period denotes the speed of the wheel, which is used to extrapolate the speed of the vehicle. This input is used in the calculation of optimized shifting to set a ratio in the variator 132 .
Motor speed data provided by sensor 240 is another automatic variable that might be fed to the microprocessor 112 . The motor speed sensor 240 operates on the same principle as the front wheel sensor 236 . The signal provided by the sensor 240 gives a motor RPM value, which can be used to verify the transmission ratio using the following calculation:
Motor RPM/fixed gear reduction/variator gear reduction
The variator gear reduction is derived from the front wheel speed sensor 236 and can be used to validate vehicle speed or transmission ratio to the “set ratio” of the control system.
Other examples of automatically generated variables include, but are not limited to:
Position of the throttle Current draw from the battery Variator setting Battery level Control settings of the motor control device (e.g., linear or s-curve), Wind Direction Wind speed Tire pressure
External data may also be provided to the microprocessor via a blue tooth antenna 260 .
The twist throttle 146 gives the motor controller 144 an input signal from the rider. Based on the amount the throttle 146 is twisted, it increases a resistance value to the main motor controller 144 , which then translates this resistance value into voltage and current supplied to the drive motor 140 . In the preferred embodiment the throttle is rated for 0-5 k resistance.
FIG. 3A is a schematic representation of the automatic operation of the shifter in accordance with one embodiment of the present invention. In one embodiment, the microprocessor 112 comprises a basic stamp board available from Parallax, Inc. of Rocklin, Calif. The microprocessor 112 can be programmed to generate lookup tables to provide optimum set points for variable inputs (described above) to obtain either the best performance or optimal efficiency of the scooter system.
In the example depicted in FIG. 3A , the microprocessor 112 receives data from the front wheel speed sensor 236 and current draw sensor 244 . The microprocessor 112 then outputs a signal to the servo 120 , which in turn provides an axial force to the variator 332 to shift in an optimal manner that minimizes current draw 244 or power drain so as to provide optimal efficiency. The data sampling speed and servo adjustment speed are adjusted to minimize power drain on the system that would otherwise cancel the efficiency gains.
As shown in FIG. 2 , microprocessor output can be shown on a display 150 . This is an “on board” display of inputs and outputs that allows the user to verify settings and measurements during the testing phase. Examples of display readouts include:
Wheel count Current amps Voltage in (current sensor for motor) Motor RPM Wheel RPM Mile per hour (MPH)
FIG. 3B is a schematic representation of the 90° gearbox in accordance with one embodiment of the present invention. The gearbox 322 comprises a servo 320 mounted with bolts 310 to the scooter frame (not shown). A coupler 323 is disposed between a threaded (worm) shaft 324 and the servo 320 . Upon rotation of the threaded shaft 324 , the wheel 326 rotates as depicted by numeral 328 , causing the shift shaft 330 to rotate. Such rotation of the shift shaft 330 is converted into an axial force.
The 90° gearbox setup is used to provide a mechanical advantage (i.e. 36:1) and to reduce the size of the protrusion from the side of the scooter.
When the system is turned on the servo motor 320 is driven towards home until the shift shaft 330 contacts the home sensor 250 (shown in FIG. 2 ). The servo is stopped and the microprocessor 112 sets the internal electronic home position, registering voltage, turns, and rotation direction. In response to inputs from the sensors, based on the last known servo position a comparison is made between the current position and the “called” position. The microprocessor 112 then drives the servo 320 to the “called” position.
FIG. 4A is a simplified schematic representation of a linear actuator in accordance with an alternative embodiment of the present invention. This embodiment uses a rack and pinion setup and can be mounted up inside of the scooter. The end 416 of the threaded shaft 424 is adapted to couple between a first tooth-like member 412 and a second tooth-like member 414 . As the servo motor rotates the shaft end 416 , the first tooth-like member 412 is driven axially and thereby provides an axial force to a member 410 that is in communication with the tooth-like member 412 and a variator (not shown).
FIG. 4B is a schematic representation of a servo motor mounted on the rear wheel in accordance with an alternate embodiment of the present invention. The servo motor 420 is connected to a shaft 430 having a threaded portion 424 adapted to couple with a threaded variator shaft (not shown). The internal threaded portion 424 allows space for the variator shaft to be pulled in and out. The servo motor 420 turns the shaft 430 thereby causing the threaded portion 424 to move the variator shaft in or out, thus adjusting the variator.
FIG. 4C is a schematic representation of an alternate servo motor design in accordance with another embodiment of the present invention. Like the embodiment depicted in FIG. 4B , the servo motor 420 in this embodiment is also mounted at the rear wheel of the scooter. However, in this embodiment, the servo motor 420 is connected to a shaft 430 having a splined portion 425 adapted to couple with a variator shaft (not shown). The servo motor 420 turns the splined shaft 430 , thereby creating an axial force on the variator shaft, thus adjusting the variator.
FIG. 4D is a schematic representation of the servo motor in communication with a hub that contains the variator in accordance with another alternate embodiment of the present invention. In this embodiment, a hub 1102 containing the variator is mounted at the rear wheel of the scooter (not shown), and the servo motor is mounted up in the scooter. The rear hub 1102 includes a housing having an axial force that encloses and protects a pulley system coupled to cables 1012 and 1014 . These cables 1012 , 1014 in turn are connected to the servo motor 420 , which alternately pulls cable 1012 or cable 1014 in order to adjust the variator inside the hub 1102 .
The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | The present invention provides a system and method for automatically adjusting a continuously variable transmission (CVT) in a motorized vehicle. A microprocessor processor in the vehicle receives data about the operating status of the vehicle from a plurality. Examples of vehicle data include vehicle speed, motor speed, throttle position, current draw from a battery, and battery level. A servo motor is in mechanical communication with the CVT and provides an axial force to adjust the CVT. The microprocessor uses lookup tables of optimal set points for vehicle data to instruct the servo motor to adjust the transmission ratio of the CVT according to the vehicle data provided by the sensors. | 5 |
This is a continuation of application Ser. No. 496,010, filed May 19, 1983 now U.S. Pat. No. 4,440,102 dated Apr. 3, 1984.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a tufting machine and method of producing tufts in a base fabric and is more particularly concerned with a tufting machine and method of tufting for producing multiple rows of tufts with single lengths of yarn.
2. Description of the Prior Art
In the past, tufting machines with laterally shiftable needle bars have been devised. U.S. Pat. No. 3,026,830 issued Mar. 27, 1962 to Bryant et al.; U.S. Pat. No. 3,109,395 issued Nov. 5, 1963 to Batty et al.; U.S. Pat. No. 3,396,687 issued Aug. 13. 1968 to Nowicki and my U.S. Pat. No. 4,366,761 issued Jan. 4, 1983 all disclose tufting machines with laterally shiftable needle bars so as to permit a needle to selectively operate with one of two or more adjacent loopers. Of those patents listed above, the patent to Bryant et al. U.S. Pat. No. 3,026,830 discloses a tufting machine which uses a disc shaped cam, the rotation of which is synchronized with the needle operation so as to shift the needle bar laterally in timed relationship to the operation of the needles. The prior art machines disclosed in the above-listed patents, all must be shifted in needle gauge increments and must therefore have quite close tolerances so that in one position all needles are in registry with a prescribed set of loopers and when shifted to another position the same needles are all in registry with another set of loopers.
Also, zig-zag tufted fabrics have been produced by shifting the base fabric or backing material by laterally moving a support beneath the needle bar. In such an operation, neither the needle bars nor the loopers are shifted. U.S. Pat. No. 3,577,943 and U.S. Pat. No. 3,301,205 show machines for doing this type of tufting.
In the past, narrow gauge tufting machines, because of the limited space between adjacent needles, have been restricted to using small diameter yarns. Such small diameter yarns are expensive to produce, break easily and do not bloom after tufting, as well as the comparable larger diameter yarns. The present invention is particularly suited to producing narrow gauge tufted products using larger diameter yarns than heretofore used, since one needle will produce two or more longitudinal rows of tufting.
In the past, the gauge of combination cut and loop pile tufting machines have been limited as to the narrowness of the gauge, due to the necessity for access to the looper assembly required for each needle. The present invention is particularly suited for use in such combination machines because it can produce narrow gauge goods without the necessity of a needle for each longitudinal row.
SUMMARY OF THE INVENTION
Briefly described, the apparatus of the present invention includes a conventional tufting machine through which a backing material is fed in a linear path across the bed of the tufting machine, so that successive transverse increments of the backing material are positioned beneath a transverse row of needles carried by the needle bar. The conventional tufting machine also has loopers below and in the vertical alignment or registry with the side of the needle for engaging, respectively, the loops of yarns inserted through the backing material by the needles.
A needle bar shifting assembly shifts the needle bar laterally back and forth during only a portion of the cycle of the needle bar, between the time and needles are retracted from the fabric and the time they reach bottom dead center, whereby the needles are in a laterally shifted condition, offset from alignment with the loopers, when they enter the fabric and are then moved back into their aligned or in registry positions, with their loopers, before they reach the position of their stroke in which the loopers engage and hold the inserted loops of yarn.
The needles are withdrawn in a straight vertical path and the natural resiliency of the backing material usually returns the transverse increment of backing material, which was laterally shifted to its normal linear path of movement.
The needle bar is usually shifted first laterally in one direction by about one-fourth the gauge of the machine, during a first down stroke of the needles, and, then, laterally by about one-fourth the gauge of the machine in the other direction, during the first portions of a second or alternate down stroke so that successive increments of the backing material are shifted in opposite directions by the penetrating needles whereby each needle and looper combination produces two longitudinal rows of tufts with the successive tufts. The amount of lateral shifting, however, can be varied, as desired.
The needle bar shifting assembly includes a shifting bar connected to the needle bar so that the needle bar is shifted therby. The needle bar shifting assembly includes a transversely moveable shifting bar, the end of which carries a plurality of spaced guide rollers which form a guide for a vertically disposed shifting bar follower. The shifting bar follower is fixed to the needle bar so that it is reciprocated vertically therewith, within the path defined by the rollers. Lateral movement of the shifting bar, moves the vertically reciprocating follower and needle bar laterally during their vertical reciprocation. Spaced cam followers on the shifting bar ride along diametrically opposed portions of the periphery of a cam or camming wheel or plate which has alternate recesses and lobes which are equally circumferentially spaced along the periphery of the camming plate. The cam is rotated in synchronization with the reciprocation of the needle bar to shift the needle bar as described above.
Accordingly, it is an object of the present invention to provide a tufting machine and process of tufting which will produce multiple rows of tufts with a single length of yarn carried by a single needle.
Another object of the present invention is to provide a tufting machine which, for the gauge of carpeting produced, is inexpensive to manufacture, durable in structure and efficient in operation.
Another object of the present invention is to provide a tufting machine which can sew two or more longitudinal rows of tufts using a single needle and single looper.
Another object of the present invention is to provide a tufting machine which requires no special adjustment for enabling a single needle to sew a plurality of longitudinal rows of tufts in a backing material.
Another object of the present invention is to provide a method and apparatus of tufting wherein a plurality of dense longitudinal rows of tufting can be produced using a relatively wide gauge machine.
Another object of the present invention is to provide an apparatus for producing, comparatively inexpensively, a finer gauge tufted product.
Another object of the present invention is to provide a process of tufting wherein the holes, created in the backing material for the tufts, are provided with a better spacing than heretofor provided.
Another object of the present invention is to provide an apparatus and method of tufting wherein a narrow gauge fabric is produced using larger diameter yarn than has heretofor been used.
Another object of the present invention is to provide a tufting process and apparatus which will create back stitches over the warp yarns and filling yarns of a woven backing material, thereby providing a relatively stronger tufted product.
Another object of the present invention is to provide an apparatus and method of tufting which will give a better distribution of tufts in the base fabric.
Another object of the present invention is to provide a method and apparatus of tufting which is particularly useful in producing selectively loop and cut pile fabric, the apparatus and method permitting greater space between adjacent needles for receiving the loopers.
Another object of the present invention is to provide a tufted product with a stronger backing material and larger diameter yarn.
Other objects, features and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings wherein like characters of reference designate corresponding parts throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially broken away side elevational view of a portion of a shiftable needle bar tufting machine constructed in accordance with the present invention, the cam and a portion of the shifting bar being rotated 90° for clarity;
FIG. 2 is a fragmentary, schematic, bottom plan view of a tufted product produced according to the present invention;
FIG. 3 is a fragmentary, schematic, top plan view of a prior art tufted product comparable to the tufted product depicted in FIG. 2;
FIG. 4 is a schematic diagram depicting the respective positions of the needles, loopers and cam during a typical operation of the tufting machine depicted in FIG. 1, the broken lines for the cam showing an alternate manner of shifting; and
FIGS. 5-18 are fragmentary side elevational views of a portion of the needle bar of the tufting machine depicted in FIG. 1, the needle bar being illustrated in successive figures as moving through one cycle (two reciprocations of the needle bar) of the machine of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in detail to the embodiment chosen for the purpose of illustrating the present invention, numeral 10 denotes generally a tufting machine of the type found in U.S. Pat. No. 3,026,830 issued to Clifford Aldine Bryant, Robert F. Hackney, and Otis C. Payne, all of Dalton, Ga. on Mar. 27, 1962, entitled TUFTING MACHINE AND METHOD FOR PRODUCING MULTI-COLOR DESIGNS IN CARPETING AND THE LIKE. This tufting machine 10 is of the type having a transversely disposed needle bar 11 which is reciprocated vertically by means of reciprocating piston rods 12 and is shifted laterally by means of a needle bar shifting assembly which includes a transversely moveable shifting bar 19, the end of which carries a plurality of spaced guide rollers 8 which form a guide for a vertically disposed shifting bar follower 9. The shifting bar follower 9 is fixed by its lower end portion to the needle bar 11 so that it is reciprocated vertically therewith, within the path defined by the rollers 8. Lateral movement of the shifting bar 11, moves the vertically reciprocating follower 9 and needle bar 11 laterally during their vertical reciprocation, in its central portion, with a slot 13 surrounding a drive shaft 14. The shift bar 19 is reciprocated laterally by means of a pair of spaced, cam followers 15a and 15b which project sidewise from bar 19. The cam followers 15a and 15b ride on the diametrically opposed peripheral portions of the periphery 16 of a disc shaped cam or camming plate 17. The disc shaped cam 17, in turn, is carried by the shaft 14 rotated in timed or synchronized relationship to the reciprocation of the reciprocating shaft 12, i.e., needle bar 11, so that upon one cycle of reciprocation from top dead center back to top dead center of the needle bar 11, the or cam 17 will have been rotated through 36° or one tenth a revolution of the cam 17.
It will be understood by those skilled in the art that the base fabric or backing material 20 is fed in a longitudinal linear path over a bed 18 on the tufting machine 10 so that successive transverse increments of the backing material are beneath the reciprocating needle bar 11 and so that the needle bar 11 extends transversely with respect to the linear longitudinal path of travel of the base fabric or backing material 20. Backing material 20 is fed intermittently by rolls (not shown) disposed on the side of the tufting machine 10 and thus, a successive increment of the backing material 20 is disposed below the needle bar 11 upon each cycle of the machine.
As in the conventional tufting machine, the needle bar 11 is provided with a plurality of evenly spaced, parallel, downwardly extending, tufting needles 21, which are arranged in one or a plurality of transverse rows. For each needle 21, there is one and only one associated looper 24 in a transversely fixed position for loop engaging action and each needle 21 is in its normal unshifted condition in registry with its looper, or is brought into a position where one side of the needle is in alignment with its associated looper 24 before the needle 21 reaches the bottom dead center position for the needles 21. Yarns 22 respectively pass through the eyes adjacent to the points of the needles 21, so that when the needle bar 11 is moved from its top dead center position, downwardly, points of the needles 21 simultaneously penetrate a transverse increment of the backing material 20 and insert their loops of yarn 22 through the backing material 20. When the needles 21 penetrate the backing material 20 sufficiently, the loops 23 of the yarns 22, are formed in and beneath the base material 20, and these loops 23 are respectively caught by the loopers 24 when the eyes of needles 21 approach bottom dead center, the loopers 24 catching the retaining the loops 23 in a conventional way and holding them for a sufficient time to permit the needles to be withdrawn in axial, vertical, linear, parallel paths from the backing material 20.
According to the present invention, the periphery or peripheral surface 16 of the circular or disc shaped cam 17 is provided with an odd number of lobes 25a, 25b, 25c, 25d and 25e, equally spaced circumferentially around cam 17. Each lobe 25a , 25b, 25c, 25d and 25e has an inclined outwardly protruding leading edge or surface 26a and an inclined inwardly protruding trailing edge or surface 26b and outer ends of which are joined by a flat or concentrically arcuate, central surface 26c. The height of each lobe 25a, 25b, 25c, 25d and 25e in the preferred embodiment is equal to approximately one-fourth the gauge of the tufting machine, i.e., one-fourth the transverse distance between the axis of one needle 21 and the axis of the adjacent needle 21. Each pair of surfaces 26a and 26b tapers outwardly.
Midway circumferentially, between each of the lobes 25a, 25b, 25c, 25d and 25e are a like number of recesses or valleys 27a, 27b, 27c, 27d and 27e, the recesses 27a, 27b, 27c, 27d and 27e being diametrically opposed to the lobes 25a, 25b, 25c, 25d and 25e, respectively. Furthermore, each recess 27a, 27b, 27c, 27d and 27 e has an inclined inwardly protruding leading edge or surface 28a and an inclined trailing edge or surface 28b which tapers inwardly, the inner ends of these edges 28 and 28b being joined by a flat or concentric e.g., arcuate central surface 28c. The depth of each valley 27a, 27b, 27c, 27d and 27e corresponds to the height of its associated diametrically opposed lobe 25a, 25b, 25c , 25d and 25e, whereby each time a lobe and a valley are in contact with a cam follower 15a or 15b it causes a laterally shifting of the shift bar 19 by a distance which is approximately one-fourth the distance between adjacent needles 21. The shifting in both directions is essentially over a period of less than one-half the period of the downstroke of the needle 21. Also, the initial shifting in one direction must occur while the needles 21 are retracted from the base material 20, i.e., prior to the penetration of the needles 21 into the backing material 20. The subsequent shifting in the other direction must occur after the needles 21 have penetrated the backing material 20, but prior to bottom dead center, i.e., the time that the hooks of the loopers 24 extend into the loops 23 of the yarns 22.
In FIG. 2 it is seen that, when using the cam 17, adjacent pairs of longitudinal rows of tufts are produced by each individual yarn 22 the back stitches 30 being in a zig zag fashion. The back stitches 30 extending diagonally in one direction and then diagonally in the other, between successive holes created by each needle 21 in the backing material 20. The tufts formed by loops 23 are, thus, staggered in each pair of longitudinal rows of tufts in the backing material and are also in parallel transverse rows. Contrary to the in line longitudinal holes 124 of the prior art, the staggered holes are not as closely adjacent to each other. Thus, the backing material 20 will not split as readily, when stretched for laying, as the comparable prior art backing material 120.
In the operation of the preferred embodiment of the machine of the invention, needles 21 begin a cycle at top dead center depicted in FIG. 5 of the drawing and being illustrated in FIG. 4 as the first position. In this position the loopers 24 are engaging the previously formed loops and the needles 21 are retracted or withdrawn out of the fabric. In FIG. 6, the needles 21 begin their travel downwardly and are shifted to the right by the cam follower 15a being received in a recess, such as recess 27b, and the cam follower 15b being engaged by a lobe 25d. It will be understood from FIG. 4 that the loopers 13 are still engaging the loops 23 to prevent a back drawing of the loops.
In FIG. 7, the needles are depicted as entering the backing material 20, with the loopers 24 still engaged in the previously formed loops 23. In the bottom portion of FIG. 4 it will be seen that the curve denoted by the numeral 40, depicts the position of the tip of a needle 21 with respect to the backing material 20 and that when the needles 21 are in the position, shown in FIG. 7, the tips of the needles 21 are just penetrating the backing material 20. It will also be seen that immediately after top dead center (T.D.C.) the leading edge 26a of the lobe 25d engages the follower 15b so as to begin the shifting of the control bar 19. By the time that the needles 21 have progressed downwardly any appreciable distance, the needles 21 have been fully shifted to the right in FIG. 1 as a result of the follower 15b riding upon the flat or slightly arcuate central portion or surface 26c of the lobe 25d. As the needle 21 continues its travel downwardly to penetrate the backing material 20, as indicated in FIG. 4 by the broken line 40 passing the backing material 20 as depicted in FIG. 7, the cam follower 15b has reached the trailing edge or surface 26a. Further movement of the needles 21 so as to penetrate and engage the backing material 20, results in all of the needles 21 moving the penetrated increment of the backing material 20, which is closely adjacent to their points of penetration, to the left, as the follower 15b rides along the trailing edge or surface 26a of the lobe 25d. The shift laterally of the increment is only one-fourth the gauge of the machine and therefore is not sufficient to alter the overall linear path of travel of backing material 20.
In FIG. 8, it is seen that the loopers 24 have released the previous loop 23, since the diagonal back stitch 30 has been laid down by the insertion of the needle 21 into the backing material 20. Since all needles 21 penetrated the backing material 20 before the cam follower 15b descended along the incline 26c, the lateral shifting of the increment of the backing material 20, which has been penetrated, will take place during the travel of the cam follower 15b along the incline surface 26c. This shifting of the backing material will correspond, in distance, to the height of the lobe 25d, i.e., the difference in the radius of the peripheral surface 16 and the radius of the surface 26c.
The needles 21 continue their descent until the needles 21 reach bottom dead center (B.D.C.) as depicted in FIG. 9. At that time, the loopers 24 are still not engaging the loops 23; however, the loops 23 have been inserted through the backing material 20 to the full extent of the travel of the needles 21.
When the needles 21 begin their ascent or retraction back toward top dead center, it will be understood that since the cam followers 15a and 15b both ride along the periphery 16 throughout this travel, the needles 21 travel along parallel linear vertical paths in registry with their loopers to top dead center.
As the needles exit from the backing material, as shown in FIG. 11, the transverse increment of backing material 20, which has been previously shifted laterally, is released and due to the natural resiliency, i.e., the fact that the backing material has not been stretched beyond its elastic limints, and/or due to the tension applied by the tufting machine in a longitudinal direction of travel to the backing material 20, this increment moves laterally, returning to the normal straight linear path followed by the backing material 20.
Even if the backing material 20 is a non-resilient web or has been stretched beyond its elastic limits, the subsequent one-half cycle of the process (a 360° or one cycle travel for the needle bar 11) will have the effect of shifting the increment in the appropriate direction, because of the positive shifting by the needles 21 of the subsequent transverse increment as will now be described.
With the emergence of the needles 21 from the backing material, the needle bar 11 can be shifted laterally to the left, at any time prior to the needles 21 again entering the backing material. The tufting machine 10, however, is programmed by the cam 17 to accomplish the initial lateral shifting (left or right, as the case may be) for that half cycle of the process during an initial part of each down stroke. Thus, upon exiting as shown in FIG. 11, the needles 21 continue their travel in their linear vertical paths, to top dead center, as shown in FIG. 12, whence the needles 21 again begin their descent from the FIG. 12 position to the FIG. 13 position. During this travel, cam follower 15b passes into valley 27b as cam follower 15a ride on lobe 25b, the effect being that the needle bar 11 is shifted left by one-fourth the distance between axes of adjacent needles 21 and the needles 21 descend to their penetrating position as shown in FIG. 14, while being so shifted.
After entry, the progressive rotation of cam 17 removes the lobe from follower 15a and removes valley 27b from follower 15b, thereby causing a right shift so as to return the needle 21 to their unshifted or normal or centerline position, as depicted in FIG. 15. The needles 21 continue their downward travel to bottom dead center as illustrated in FIG. 16, and then begin their ascent, as illustrated in FIG. 17. As in the previous one half cycle, the loopers 24 engage the loops 23 while the needles 21 travel upwardly along their normal centerline axes, the needles 21 traveling linearly along these axes during the entire period in which they are ascending from bottom dead center to top dead center. As the needles exit, the backing material 20, the resiliency or springiness of the material cause the second increment of material which has been provided with the loops to spring back laterally into their original path of linear travel. The needles 21 then continue their upward travel to the top dead center position as depicted in FIG. 5 and commence another cycle of the process or machine.
With backing material 20 which does not readily spring back to its linear travel position, double shifting of the backing material 20 by the needles 21 during a single cycle of the machine will solve this problem. In this alternate form of operation, as depicted in FIG. 4, this double lateral shifting of the backing material 20 is accomplished by providing the periphery of cam 17 with twice the number of lobes and valleys, a lobe 126 occurring immediately prior to each valley 27a, 27b, 27c, 27d, 27e and a valley 127 occurring immediately prior to each lobe 25a, 25b, 25c, 25d, 25e.
When the machine is operated in this alternate mode, the needles are first shifted in one lateral direction while they are free of the backing 20 then the needles 21 are inserted in the backing and shifted in the other lateral direction for accomplishing its tufting operation, as described for the preferred operation; however, the additional lobes 126 and valleys 127 causes the needles 21 to be shifted laterally, a second time, during each upstroke, and prior to the retraction of the needles 21 from the backing material 20, the shifting being in the same direction and to the same extent as the shifting took place during the initial portion of the cycle when the needles 21 were free of the backing material 20. The result, therefore, is that the increment of the backing material 20 which was shifted in one direction for the tufts inserting operation is shifted by the needles 21 back to its original linear path of travel, before the needles 21 are retracted from the backing material 20.
While we have chosen to describe the needles as shifting by one fourth the gauge of the machine, so as to produce two rows of tufts spaced part by one half the gauge, it will readily be understood that the needles 21 can be shifted by an increment desired or shifted successively from the normal position in only one direction, rather than in alternate directions. Thus, any reasonable number of longitudinal lines of tufts can be produced using a single needle 21 by shifting its appropriately to the left or right, as described. Of course, a longitudinal line of tufting can be produced by cycling the needles 21 without shifting them at all.
The present invention is equally applicable to tufting machines for producing both cut pile and loop pile, it being understood that the term "looper" or "looper means" applies equally to a loop pile looper or to the cut pile looper and its knife. When I state that the loop is released by the looper or the hook of the looper, I mean that the loop 12 can be released, as a loop or can be servered by a knife and hence released as cut pile. The looper can be a single looper or a plurality of loopers in vertical alignment such as in a combination cut and loop pile machine wherein certain of the loops formed by a single needle are cut and others are uncut. The machine and process of the present invention is particularly suited for use in such combination cut and loop pile machines since the looper construction for each needle has, in the past, limited the narrowness of the gauge of the machine to relatively wide distances between adjacent needles.
It will be obvious to those skilled in the art that many variations may be made in the embodiment chosen for the purpose of illustrating the invention without departing from the scope thereof as defined by the claims. | A laterally shiftable needle bar of a tufting machine, carrying a plurality of laterally spaced needles, is reciprocated in a vertical path for simultaneously inserting loops of yarn, carried by the needles, through a base fabric, the fabric being fed in a linear longitudinal path beneath the needles. Each needle has an individual looper below the base fabric, in registery and cooperating with the needle for engaging and temporarily holding the loop of yarn, inserted by the needle through the base fabric, as the needle is retracted.
During a first portion of a cycle of the needle bar, prior to the insertion of the needles through the base fabric, a needle bar shifting assembly shifts the needle bar laterally, in one direction or the other. Then, after the needles have penetrated the base fabric, the needle bar shifting assembly shifts the needle bar laterally in an opposite direction, so as to cause the needles to move, the penetrated portion of the base fabric laterally out of its normal linear path and align the needles with their loopers beneath the base fabric for engagement of the loops by the loopers, as the needles are withdrawn vertically from the base fabric. The resiliency of the base fabric returns the shifted portion of the base fabric to its original linear path across the machine and the yarn inserting cycle is then repeated. By appropriate manipulating of the lateral shifting of the needle bar one or, indeed, a plurality of longitudinal rows of tufts are produced by each needle and its individual looper. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present disclosure relates to subject matter contained in priority Korean Application No. 10-2006-0098068, filed on Oct. 9, 2006, which is herein expressly incorporated by reference in its entirety.
BACKGROUND
[0002] The present disclosure relates to a dryer and method of controlling the same.
[0003] Generally, a drum-type dryer is designed to perform the drying operation while rotating laundry loaded in a dry drum. The laundry rotates and drops by the rotation of the dry drum.
[0004] Further, High-temperature dry air inhaled into the dry drum is mixed with the laundry to vaporize the moisture soaked in the laundry. The drum-type dryer may be classified into a condenser-type dryer and an exhaust-type dryer. The former is designed such that the air in the dry drum is directed to a condenser and a heater and is then returned to the dry drum. That is, the air circulates in the dryer without being exhausted out of the dryer. The latter is designed such that the air in the dry drum is directed to the condenser so that the moisture contained in the air can be eliminated and is then exhausted out of the dryer.
[0005] Particularly, according to the condenser-type dryer, the air circulating in the dryer absorbs the moisture from the laundry loaded in the drum and then passes through the condenser to be lowered in its temperature by a heat-exchange. As the temperature of the air is lowered, the moisture contained in the air is condensed. The condensed water is pumped out by a condensing pump and is then exhausted to outside. On the other hand, according to the exhaust-type dryer, high-temperature high-moisture air absorbing moisture from the laundry in the drum is exhausted out of the dryer via a lint filter.
[0006] Here, both of the exhaust-type and condenser type dryers are the same in that heat-exchange between the high-temperature dry air and the laundry is incurred as the laundry lifts and drops by the rotation of the drum.
[0007] In addition, the dryer may be classified into an electric dryer and a gas dryer depending on how to heat up the air which is to be supplied into the dry drum. That is, the dryer is classified into an electric dryer which heats the air by using an electric heater, and a gas dryer which heats the air through gas combustion.
[0008] Meanwhile, according to the electric dryer, a plurality of different heaters are installed in a drying duct, wherein a high-temperature heater which generates high calories and a low-temperature heater which generates low calories are installed therein.
[0009] Particularly, the high and low temperature heaters repeat on/off simultaneously or individually when the dry operation is performed, thereby controlling an inside of the dry drum to be maintained at a preset temperature.
[0010] Further, an electric leakage breaker is provided in the conventional electric dryer. And, the electric leakage breaker detects the leakage current greater than at least 25 mA.
[0011] On the contrary, according to the conventional dryer, the leakage current of 5 mA is generated when the dryer is abnormally stopped, and therefore the insulation of the heater is broken due to the moisture inside the dryer, however the electric leakage breaker does not detect the leakage current. In this case, there is a risk of electric shock if a user touches the dryer.
SUMMARY
[0012] The present embodiment suggests a dryer and method of controlling the same. In accordance with the embodiments of the invention, there is provided a dryer, including, a heater for heating the air which is to be directed to a dry drum; a motor for rotating the dry drum; a power supply unit for supplying electric current to the heater and the motor; a heater relay for selectively applying electric current to the heater; a motor relay for selectively applying electric current to the motor; a safety relay for selectively applying electric current from the power supply unit to the respective relay; and a control unit for cutting off electric current by turning off the safety relay when an abnormal stop occurs, after the control unit determines whether the abnormal stop occurs during a drying operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present embodiment will be more fully understood with reference to the accompanying drawings.
[0014] FIG. 1 is a cross-sectional view showing a structure of a dryer according to the present embodiment.
[0015] FIG. 2 is a block diagram showing a system of a dryer for embodying the concept of the present embodiment.
[0016] FIG. 3 is a circuit diagram of a dryer according to the present embodiment.
[0017] FIG. 4 is a flow chart showing a method of controlling a dryer according to the present embodiment.
DETAILED DESCRIPTION
[0018] Hereinafter, the present embodiment will be described by way of illustrative examples with reference to the accompanying drawings.
[0019] FIG. 1 schematically shows a cross-sectional view of a structure of a dryer according to the present embodiment. Hereinafter, the condenser-type dryer will be explained as a preferred embodiment.
[0020] Referring to FIG. 1 , the dryer 10 according to the preferred embodiments of the present invention includes a cabinet 11 forming an exterior, a front frame 22 and a front cover 23 which are connected to a front of the cabinet 11 , a cylindrical drum 12 formed inside the cabinet 11 , a door 13 opening/closing an inlet of the drum 12 as it is mounted on a front portion of the drum 12 , a belt 21 rotating the drum 12 as it is surrounded around an outer circumference of the drum 12 , and a drum support 24 allowing a rear of the drum 12 to be supported on the cabinet 11 . Here, the front portion of the drum 12 is supported by the front cover 23 .
[0021] In addition, the dryer 10 further includes a motor shaft 171 connected with the belt 21 , a motor 17 applying a rotational force to the belt 21 as it is connected with the motor shaft 171 , and a cooling fan 16 inhaling indoor air as it is rotated by receiving the rotational force.
[0022] In addition, the dryer 10 further includes a drying fan 18 circulating the air inside the drum as it is connected with the motor shaft 171 at an opposite side of the cooling fan 16 , and a drying duct 19 transporting the air inhaled by the drying fan 18 to the drum 12 , in which a heater 20 is installed.
[0023] In addition, the dryer 10 further includes a door lint filter 14 which is formed in a rear of the door 13 to filter fluffs in humid air which is discharged from the drum 12 , a body lint filter 151 for filtering the humid air which is passed through the door lint filter 14 , and a circulation duct 15 through which the air passed through body lint filter 151 moves to a condenser (not shown).
[0024] In addition, the heater 20 includes a high-temperature heater 201 generating heat of approximately 1750 W, and a low-temperature heater 202 generating heat of approximately 750 W. Further, a high-temperature sensor 26 for sensing the temperature of the air which passes through the drying duct 19 is mounted on the surrounding of the heater 20 , i.e. the rear of the dry drum 12 , and a low-temperature sensor 27 for sensing the temperature of the humid air which passes through the dry drum 12 is mounted on the front of the dry drum 12 . Here, various kinds of sensor can be applied as the temperature sensor, for example a thermistor which changes its resistance in accordance with a change in temperature can be used therein.
[0025] Hereinafter, the operation of the dryer will be described.
[0026] First, if electric power is applied to the dryer, the motor 17 starts to rotate and the heater 20 attached to the inside of the drying duct 19 generates heat. After that, the drum 12 is rotated by the rotation of the belt 21 connected to the motor shaft 171 . Particularly, the drum 12 rotates about the drum support 24 as a rotation axis. Further, a dry object in the drum 12 rotates along an inner wall of the drum 12 as the drum 12 rotates, and drops by self-weight at a top of the drum. Here, the dry object is raised by a lifter (not shown) disposed at the inner wall of the drum 12 .
[0027] Meanwhile, the drying fan 18 connected to the motor shaft 171 is operated at the same time of the rotation of the motor 17 , to inhale the circulation air passed through the condenser. The inhaled circulation air rises along the drying duct 19 and becomes a high-temperature and dry air via the heater 20 . Further, the high-temperature and dry circulation air passes through the drum 12 while absorbing the moisture from the dry object, and thus, it becomes a high-temperature and humid air.
[0028] In addition, the high-temperature and humid air is again filtered by the door lint filter 14 and the body lint filter 151 , and then is directed to the condenser along the circulation duct 15 .
[0029] In addition, when the cooling fan 16 connected to the motor shaft 171 is rotated to inhale the indoor air out of the dryer. And then, the inhaled indoor air is flowed to the condenser through the cooling fan 16 .
[0030] Here, the high-temperature and humid air flowed along the circulation duct 15 and the indoor air inhaled by the cooling fan 16 are passed through the condenser with being crossed to each other. Also, the high-temperature and humid air and the indoor air just exchange heat, not being mixed due to the configuration of the condenser.
[0031] Therefore, the high-temperature and humid air is deprived of heat by the indoor air while passing through the condenser, thereby being changed into a low-temperature and humid air. In addition, as temperature is lowered, moisture contained in the air is condensed and dropped down onto the bottom of the condenser, and then flowed to a sump (not shown) where the condensed water is collected.
[0032] FIG. 2 shows a block diagram of a system of a dryer according to the preferred embodiments of the present invention, and FIG. 3 shows a circuit diagram of a dryer according to the preferred embodiments of the present invention.
[0033] Referring to FIG. 2 , the system of the dryer according to the preferred embodiments of the present invention includes a control unit 100 , a key input unit 110 for inputting dry conditions and operation commands, a driving unit 130 driving the heater 20 or the motor 17 depending on the input dry condition, and a temperature sensor for sensing the temperature of the air which is heated by the heater 20 , wherein the temperature sensor includes a high-temperature sensor 26 and a low-temperature sensor 27 .
[0034] In addition, the system of the dryer includes a safety relay 140 which cut off the electric current due to the malfunction of the dryer, and a memory 120 in which various information such as the command information input by the key input unit 110 and the temperature information transmitted from the temperature sensors 26 , 27 are stored.
[0035] Referring to FIG. 3 , the dryer according to the preferred embodiments of the present invention intermittently transmits the electric current from the power supply unit 180 to the driving unit via the safety relay 140 .
[0036] Further, the on/off of the high and low temperature heaters 210 , 220 are controlled by a high-temperature heater relay 150 and a low-temperature heater relay 160 , respectively. The on/off of the motor 17 is controlled by a motor relay 170 . And, the high-temperature heater relay 150 , the low-temperature heater relay 160 and the motor relay 170 are parallel connected to the safety relay 140 .
[0037] Therefore, the high and low temperature heaters 210 , 220 and the motor 17 are turned on/off by the respective relay 150 , 160 , 170 , independently. And, if the safety relay 140 is turned off, then all of the high and low temperature heaters 210 , 220 and the motor 17 are turned off,
[0038] FIG. 4 shows a flow chart of a method of controlling a dryer according to the preferred embodiments of the present invention.
[0039] Referring to FIG. 4 , dry conditions are input by a key input unit (S 110 ), and operation commands are input by a operation button (S 111 ).
[0040] Particularly, if the operation commands are input, electric current is applied into the dryer and the safety relay 140 is turned on (S 112 ). And, the motor 17 and the high and low temperature heaters 210 , 220 are turned on. And, the motor 17 is rotated at a preset speed according to the input dry conditions, and the high and low temperature heaters 210 , 220 are repeatedly turned on/off to maintain the inside of the drum at a preset temperature.
[0041] Meanwhile, the control unit 100 determines in real time whether an abnormal stop, such as a stop command is input by the user or an overheating in the dry drum is occurred because the filter is blocked, is occurred or not (S 114 ).
[0042] If the abnormal stop is not occurred during the whole drying operation, and then the drying operation is processed according to the input dry condition (S 200 ). And, the operation of the dry is decided to stop or continue after determining whether the dry is completed or not (S 201 ).
[0043] On the other hand, the abnormal stop is occurred during the drying operation, the high temperature heater is previously turned off (S 115 ), and the low-temperature heater is turned off (S 116 ). And, after the motor is finally stopped (S 117 ), the safety relay 140 is turned off (S 118 ). And, if the cause of the abnormal stop is determined by the control unit 100 to be solved (S 119 ) after determining whether the cause is solved or not, the drying operation is normally carried out (S 200 and below steps are carried out) according to the input dry condition.
[0044] However, if the cause of the abnormal stop is not solved, the operation of the dry is completed. Here, the expression “the cause of the abnormal stop is solved” means that the user repress the operation button after pressing the stop button, or that the user cleans the filter after he/she recognizes a filter block signal.
[0045] As described in the above description, the electric current, which is to be supplied into the power supply unit 180 , is prevented from being leaked out by stopping the heater and the motor as well as by turning off the safety relay 140 when the abnormal stop is occurred. Therefore, it is possible to prevent the user from being struck by the electric current leaked around the surface of the dryer. | The present disclosure suggests a dryer and method of controlling the same. Disclosed is a dryer, comprising: a heater for heating the air which is to be directed to a dry drum; a motor for rotating the dry drum; a power supply unit for supplying electric current to the heater and the motor; a heater relay for selectively applying electric current to the heater; a motor relay for selectively applying electric current to the motor; a safety relay for selectively applying electric current from the power supply unit to the respective relay; and a control unit for cutting off electric current by turning off the safety relay when an abnormal stop occurs, after the control unit determines whether the abnormal stop occurs during a drying operation. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to an optical drive suitable to write optical storage discs and comprising means for accessing at least one central database which may be accessed by a plurality of optical drives to derive write strategy information assigned to known disc types. Furthermore, the present invention relates to a method for determining the write strategy of an optical drive, said method comprising the following steps: a) obtaining disc type identification information from a disc inserted into said optical device; and b) determining whether said inserted disc is a disc of a known type on the basis of said disc type identification information.
BACKGROUND OF THE INVENTION
[0002] In connection with optical drives, for example CD-R(W), DVD±(W) or BD-R(e), it is very important to be able to write or record as many inserted discs as possible. A problem in this context is that discs distributed by different manufacturers very often have different characteristics as regards the necessary write strategy. Discs requiring different write strategies are referred to as discs of different types herein. If the optical drive is not able to find a suitable write strategy, the simplest way to proceed is to reject the disc. However, each time a disc is rejected by the optical drive, the user in many cases will blame the optical drive and not the inserted disc.
[0003] One first attempt to solve this problem is to increase the writability by storing suitable write strategies for different disc types in a local database of the optical drive. Such a known first attempt is shown in the flowchart in accordance with FIG. 1 .
[0004] As soon as a disc is inserted in step S 1 , disc type identification information which is provided on every disc is read by the optical drive to identify the type of the inserted disc in step S 2 . This disc type identification information is for example known as ADIP (Address In Pre-groove) to the person skilled in the art. Then, the local database (memory) is searched for an entry matching the disc type identification information in step S 3 . If the disc type is found in the local database, in step S 4 the disc is regarded as a disc of a known type and it is proceeded to step S 5 . In step S 5 it is checked whether the speed v recording the user wants to record at is lower than or equal to the maximum speed v max the disc is designed for, wherein this maximum speed v max is obtained via the disc type identification information. If the speed v recording the user wants to record at is higher than the maximum speed v max , in step S 6 the write strategy WS suitable for the inserted disc and stored in the local database is used. If the speed v recording the user wants to record at is lower than or equal to the maximum speed v max , in step S 9 the write strategy WS is obtained via the disc type identification information. In both cases, in step S 10 the write strategy WS parameters are optimised and the disc is written is step S 11 . However, if in step S 4 the disc type of the inserted disc is not found in the local database, it is proceeded to step S 7 . In step S 7 it is also determined whether the speed v recording the user wants to record at is lower than or equal to the maximum speed v max the disc is designed for. If this is not the case, the disc is rejected in step S 8 . Only if it is determined in step S 7 that the speed v recording the user wants to record at indeed is lower than or equal to the maximum speed v max the disc is designed for, it is branched to step S 9 where the write strategy WS is obtained via the disc type identification information as described above.
[0005] A problem with this approach is that the local database in this case is filled by the manufacturer. Therefore, the local database is not complete since there are many disc types that do not comply with the standard. Furthermore, the local database does not contain disc types coming on the market after the optical drive is fabricated. As a result, with this first attempt, during time more and more discs inserted by the user will be rejected by the optical drive, and this will annoy the user.
[0006] To overcome the problems that still exist with the above first attempt, the user in accordance with a second attempt is provided with the possibility to update the local database. This can be achieved by flashing the optical drive for example with a flash disc. Another possibility is to update the local database on the basis of a central database which may be accessed by a plurality of optical drives (for example via the internet) as proposed in US 2003/0123355 A1.
[0007] A third, more successful attempt to solve the above mentioned problem is to provide optical drives that have the ability to learn and are therefore called “smart drives”. FIG. 2 illustrates the operation of such a smart optical drive.
[0008] As soon as a disc is inserted in step S 1 of FIG. 2 , also with this third attempt, disc type identification information (ADIP) is read by the optical drive to identify the type of the inserted disc in step S 2 . Then, the local database is searched for an entry matching the disc type identification information in step S 3 . If the disc type is found in the local database, in step S 4 the disc is regarded as a disc of a known type and it is proceeded to step S 5 . In step S 5 the write strategy WS is obtained via the local database. Then, in step S 6 the write strategy WS parameters are optimized. In step S 11 the write settings, for example tilt etc., are optimized, and the disc is written in step S 12 . If in step S 4 it is determined that a disc of an unknown type is inserted into the optical drive, in contrary to the above first and second attempts with the third attempt the optical drive tries to write the inserted disc of the unknown type. In this context in step S 7 the disc type identification information (ADIP) is used and in step S 8 the best possible write strategy WS is determined. If this best write strategy WS is within a spec at step S 9 , it is branched to step S 6 where the respective write strategy WS parameters are optimized, as explained above. In case of such a successful attempt to write the inserted disc of an unknown type, the local database is updated on the basis of the respective experiences, i.e. the optical drive in such a case has learned how to write the disc of the inserted type. The next time when a disc of this type is inserted, the optical device already knows this disc type in step S 4 . Only if in step S 9 it is determined that the best write strategy WS is not within the spec, the disc is rejected in step S 10 .
[0009] With the attempts explained above the number of discs rejected by an optical drive may be reduced considerably, but it might still be regarded as being too high by some users.
[0010] On the other hand there exists a problem in that in the worst case the combination of a specific drive design and a specific disc design may lead to the result that trying to write to the disc leads to a (self) destruction of the drive (damage of the optical unit, laser burn out).
[0011] It is therefore the object of the present invention to further develop the optical drives and the methods mentioned at the beginning such that the number of discs rejected by an optical drive is further reduced to the absolute necessary minimum.
SUMMARY OF THE INVENTION
[0012] This object is solved by the features of the independent claims. Further developments and preferred embodiments of the invention are outlined in the dependent claims.
[0013] In accordance with a first aspect of the present invention, an optical drive of the type mentioned at the beginning is characterized in that it is adapted to provide said central database with at least a part of disc type identification information obtained from an inserted disc, if said inserted disc is of an unknown disc type. Whether the disc is of a known or an unknown type may be determined on the basis of the central database and/or on the basis of a local database, as will be explained in more detail below. By this solution it is ensured that it is immediately noticed at the central database, if a disc of a new type enters the market. Therefore, for example people at a test facility are able to test the new disc type and to update the central database with a suitable write strategy for this new disc type. In the worst case it is discovered at the test facility that the combination of the new disc type and the optical drive is catastrophic and might lead to a drive damage. In this case the only possible write strategy WS information is that the disc has to be rejected to prevent a drive damage. After the update of the central database all optical drives that access the central database may benefit from the new entry.
[0014] In accordance with a highly preferred embodiment of the optical drive in accordance with the present invention the optical drive is further adapted to provide said central database with experiences made by trying to write to said inserted disc, particularly to an inserted disc of an unknown disc type. Thereby, it is for example also possible for the central database to provide write strategy information that does not also depend on the disc type but also on the type of optical drive. Furthermore, with this solution an optical drive is enabled not only to learn from itself, but also from other optical drives that supply the central database with data. Another advantage of the network built up in this way is that older optical drives profit from newer, more intelligent optical drives, since in essence the network is as smart as the most intelligent optical drives. Therefore, such an optical drive may be called an “ultra smart optical drive” compared to the “smart optical drives” mentioned above.
[0015] In this context it is possible that said experiences comprise write strategy WS information that was successfully applied to said inserted disc. By this solution the test facility mentioned above may for example be omitted.
[0016] However, it is also preferred that said experiences comprise write strategy WS information that was not successfully applied, particularly if trying to write lead to a damage of the optical drive.
[0017] In this connection said write strategy WS information comprises at least one bit indicating whether the inserted disc has to be rejected.
[0018] With preferred embodiments of the optical drive in accordance with the present invention it comprises a local database containing write strategy WS information for at least some known disc types. However, if access to the central database is possible without problem for example via the internet, it is also possible that only the central database is used, even if this is not preferred.
[0019] If the optical drive comprises a local database, it is preferred that the optical device is adapted to update its local database on the basis of said central database.
[0020] Furthermore it is preferred in this context that the optical device is adapted to update its local database on the basis of said experiences. This may be achieved for example as outlined with reference to FIG. 2 at the beginning.
[0021] For all embodiments of the optical drive in accordance with the present invention it is preferred that for writing to said inserted disc, it uses write strategy WS information that is stored in said local database and/or in said central database, if said inserted disc is a disc of a known type.
[0022] In accordance with a further embodiment of the present invention, an optical drive of the type mentioned at the beginning is characterized in that it is adapted to reject an inserted optical storage disc of a known disc type, if it derives from said write strategy WS information that writing to an inserted disc might lead to a damage of said optical drive.
[0023] The central database preferably is contacted via the internet. In this case an internet controlled emergency brake is realized to prevent a disc damage. The connection to the central database can be made on a regular basis and/or at the time a disc of a unknown type is inserted. As with all embodiments mentioned herein, the user preferably can decide whether internet connections are made automatically or not. The central database is for example filled by data coming from a test facility. At this facility people are testing new discs and are looking for catastrophic discs that might lead to a drive damage. This solution may be referred as a passive solution. However, there further exists an active solution wherein the central database is (also) filled by data provided by optical drives. This active solution will be described in greater detail with reference to FIG. 6 .
[0024] In any case it is preferred that the optical drive comprises a local database containing write strategy WS information for at least some known disc types.
[0025] In this connection it is preferred that the optical drive is adapted to update its local database on the basis of said central database.
[0026] The write strategy WS information preferably comprises at least one bit indicating whether the inserted disc has to be rejected.
[0027] In accordance with a second aspect of the present invention the method for determining the write strategy of an optical drive mentioned at the beginning is characterized by the following step: c) providing a central database which may be accessed by a plurality of optical drives with at least a part of said disc type identification information, if said inserted disc is of an unknown disc type. By such a method the same advantageous and characteristics as with the optical drive in accordance with the invention are achieved. Therefore, to avoid repetitions, at this point reference is made to the corresponding above explanations in connection with the optical drive in accordance with the invention.
[0028] The same applies for the following features characterizing preferred embodiments of the method in accordance with the invention.
[0029] Preferably, the method comprises the following additional steps: d) if said inserted disc is a disc of a unknown type, trying to write to said inserted disc with a write strategy WS determined on the basis of said disc type identification information; and e) if trying to write to said inserted disc in said step d) was successful, providing said central database with write strategy information used to successfully write to said inserted disc.
[0030] Alternatively or additionally it is possible that the method further comprises the following steps: d) if said inserted disc is a disc of an unknown type, trying to write to said inserted disc with a write strategy WS determined on the basis of said disc type identification information; and f) if trying to write to said inserted disc in said step d) was not successful, providing said central database with experiences made by trying to write to said inserted disc. In this connection unsuccessful attempts to write may be divided into two error classes: Soft errors and drive failure. Soft errors result in a not well-written disc, without any harm done to the drive. For example, the laser power of the drive is insufficient to write the disc at the right power. Drive failure means that part of the drive is malfunctioning as a result of the writing procedure and that the drive should be serviced. For example, this can be a broken laser or overheated chip. The information of the type of drive and the disc ID in such a case is preferably send to the central database. This means that all discs of this type will not be burned by similar drives. For example, a test facility can now take a look at these discs and see if the problem is specific to that single drive or specific to the drive type.
[0031] Furthermore, it is preferred that said step b) comprises accessing a local database and/or said central database.
[0032] In accordance with a further embodiment of the present invention the method for determining the write strategy of an optical drive mentioned at the beginning is characterized in that in said step b) determining whether said inserted disc is a disc of a known type is performed on the basis of a local database which is updated via the internet, and in that said step b) comprises rejecting said inserted disc without trying to write to it, if it is a disc of a known type which might lead to a drive damage. Also in this case an internet controlled emergency brake is realized to protect the drive.
[0033] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a flowchart illustrating a first attempt to solve the object of the invention in accordance with the prior art;
[0035] FIG. 2 is a flowchart illustrating a third attempt to solve the object of the invention in accordance with the prior art;
[0036] FIG. 3 is a flowchart illustrating a preferred embodiment of the method in accordance with the present invention;
[0037] FIG. 4 is a schematic diagram illustrating a network of a plurality of optical drives and a central database;
[0038] FIG. 5 is a simplified block diagram illustrating an embodiment of the optical drive in accordance with the present invention; and
[0039] FIG. 6 is a flowchart illustrating a further preferred embodiment of the method in accordance with the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0040] FIGS. 1 and 2 which illustrate first and third attempts in accordance with the prior art were already explained in the introduction to the description.
[0041] FIG. 3 is a flowchart illustrating a preferred embodiment of the method in accordance with the present invention, wherein the reference numerals used in the following are directed to FIG. 5 which is explained later. When a disc 16 is inserted in step S 1 of FIG. 2 , disc type identification information is read by the optical drive 10 to identify the type of the inserted disc in step S 2 . The disc type identification information particularly may be the ADIP. Then, the local database 18 is searched for an entry matching the disc type identification information in step S 3 . If the disc type is found in the local database 18 , in step S 4 the inserted disc 16 is regarded as a disc of a known type and it is proceeded to step S 5 . In step S 5 the write strategy WS is obtained via the local database 18 . Then, in step S 6 the write strategy WS parameters are optimized. In step S 13 write settings, for example tilt etc, are optimized, and the disc is written in step S 14 .
[0042] If in step S 4 it is determined that a disc 16 of a unknown type is inserted into the optical drive 10 , the optical drive 10 contacts a central database 14 via the internet to provide the central database 14 with the disc type identification information.
[0043] If a network (see FIG. 4 ) is formed by a plurality of optical drives 10 , 22 , 24 , 26 operating in this way and at least one central database 14 which may be accessed by the plurality optical drives 10 , 22 , 24 , 26 , it is ensured that it is immediately noticed when a disc of a new disc type enters the market. If such a disc of a new type is detected, a suitable write strategy WS may be determined for example by a test facility 28 which provides the central database 14 with the respective information.
[0044] Referring back to FIG. 3 , in step S 8 the disc type identification information (ADIP) is used and in step S 9 the best possible write strategy WS is determined. Only if in step S 10 it is determined that the best write strategy WS is not within the spec, the disc is rejected in step S 11 . However, if this best write strategy WS is within the spec at step S 10 , the central database 14 at step S 12 is provided with the determined best write strategy WS for the inserted disc 16 , i.e. with the experiences made by successfully trying to write to the inserted disc 16 . From this moment on, the inserted disc 16 may be handled as a disc of a known type by the whole network. Furthermore, it is branched to step S 6 where the write strategy WS parameters are optimized before in step S 13 write settings are optimized. Finally, in step S 14 the inserted disc is written. As it is indicated by the arrows between steps S 3 , S 5 , S 6 and S 13 , the optical drive 10 not only provides the central database 14 with its experiences, but also updates its local database (memory) accordingly.
[0045] FIG. 5 is a simplified block diagram illustrating an embodiment of the optical drive 10 in accordance with the present invention. The optical drive 10 comprises a read/write unit to which a disc 16 is inserted. The whole optical drive 10 is controlled by a controller 20 , as indicated by the respective arrows. Furthermore, the optical drive 10 comprises means 12 (for example a modem) adapted to access a central database 14 containing write strategy WS information at least for different disc types but in some cases possibly also for different types of optical drives, as mentioned above. The optical drive 10 shown in FIG. 5 comprises a local database 18 which also contains write strategy WS information for different disc types, wherein this local database is updated on the basis of both, the central database 14 and experiences made by the optical drive 10 . Since the optical drive 10 shown in FIG. 5 is not only able to learn by itself (smart drive) but also from all optical drives 10 , 22 , 24 , 26 ( FIG. 4 ), the optical drive 10 in accordance with FIG. 5 may be called an “ultra smart drive”.
[0046] FIG. 6 is a flowchart illustrating a further preferred embodiment of a method in accordance with the present invention, wherein the reference numerals used in the following are again directed to FIG. 5 already explained. The method illustrated in FIG. 6 is an active solution for realizing an emergency brake to protect the drive against catastrophic discs, i.e. discs which might lead to a damage of the drive if a writing process is carried out. In cases where it is determined that no catastrophic disc is inserted, i.e. in the absolute plurality of cases, the method according to FIG. 3 preferably is carried out simultaneously or afterwards to optimize the writing process.
[0047] When a disc 16 is inserted in step S 1 of FIG. 6 , disc type identification information is read by the optical drive 10 to identify the type of the inserted disc in step S 2 . The disc type identification information particularly may be the ADIP. Then, the local database 18 is searched for an entry matching the disc type identification information in step S 3 . The local database 18 contains at least write strategy WS information directed to the question whether a disc is catastrophic or not. However, with preferred embodiments the local database 18 also contains write strategy WS information which is suitable to optimize the write strategy WS, if a disc is not catastrophic, for example as discussed in connection with FIG. 3 . The local database 18 is updated by a central database 14 on a regular basis. Although not shown in FIG. 6 , it is also possible to update the local database 18 each time when an inserted disc 16 is of an unknown type. If it is determined in Step S 4 that the inserted disc 16 is of a known type and is catastrophic, the inserted disc is rejected in step S 4 to protect the drive. If the inserted disc 16 is not known to be catastrophic, in step S 6 it is tried to write the disc. If it is determined in step S 7 that no error occurred, everything is fine and the method ends in step S 8 . If an error occurred, the local database 18 is updated in step S 9 with the experiences made by the attempt to write. Then the kind of error is investigated in step S 10 . If a so called soft error occurred, i.e. an error that resulted in a not well-written disc but did not damage the drive, the illustrated method ends in step S 11 . Otherwise, if no soft error but a drive failure occurred, i.e. the drive was damaged, the central database 14 is updated accordingly via the internet in step S 12 . In accordance with the illustration of FIG. 6 , the central database 14 is additionally updated by a test facility 30 . For example, the test facility 30 takes a look at all discs reported to be catastrophic to see if the problem was specific to that single drive or specific to the drive type. In cases where the problem was specific only to a single drive the entry that the disc type is catastrophic will be removed from the central database 14 to reduce the number of disc rejections.
[0048] Although not shown in FIG. 6 , it is also possible that the drive informs the central database 14 not only in cases where a drive failure occurred, but in all cases where an unknown disc type was inserted or at least in all cases where any error occurred in the attempt to write to an unknown disc type.
[0049] The invention can be applied to all optical drives, which have access to a central database, particularly via the internet. This means at least all PC drives and drives mounted in stand-alone products connected to the internet.
[0050] Finally it is to be noted that equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims. | The present invention relates to an optical drive ( 10 ) suitable to write optical storage discs and comprising means for accessing at least one central database ( 14 ) which may be accessed by a plurality of optical drives to derive write strategy information assigned to known disc types. In accordance with the present invention the optical drive ( 10 ) is adapted to provide said central database ( 14 ) with at least a part of disc type identification information obtained from an inserted disc ( 16 ), if said inserted disc ( 16 ) is of an unknown disc type. Furthermore, the present invention relates to a method for determining the write strategy of an optical drive ( 10 ). | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a bearing device for a motor used for various types of OA apparatus.
2. Description of the Related Art
In recent years, a reduction in the cost of electronic apparatus employed in the field of, for example, office automation has advanced, and thus there has been a demand for an inexpensive motor for such electronic apparatus, which is the heart of a driving system thereof. The cost of the motor is greatly affected by the cost of a bearing element. A highly reliable miniature ball bearing is very expensive, while a relatively inexpensive oilless slide bearing is slightly less reliable than the miniature ball bearing. Thus, in order to achieve a reduction in the cost of the motor, there has been a demand for a highly reliable oilless slide bearing.
The structure of a bearing device for a conventional motor will be described below.
FIG. 6 shows an axial fan motor which is a typical example of a motor employing the above-mentioned oilless slide bearing. In FIG. 6, reference numeral 1 denotes a shaft; reference numerals 2 and 3 respectively denote a rotor frame side oilless slide bearing and an anti rotor frame side oilless slide bearing which rotatably support the shaft 1; reference numeral 4 denotes a thrust plate which axially supports loads in the thrust direction; reference numeral 5 denotes a snap ring for stably bringing the thrust plate 4 into contact with an end surface of the anti rotor frame side oilless slide bearing 3 to rotate the thrust plate 4 together with the shaft 1.
Reference numeral 6 denotes a stator boss for fixedly accommodating the oilless slide bearings 2 and 3; reference numeral 7 denotes a stator boss supporting portion for fixedly supporting the stator boss 6; reference numeral 8 denotes a rotor frame which is coupled to the shaft 1 and is thus rotatable together with the shaft 1; reference numeral 9 denotes a stator fixed to an outer peripheral portion of the stator boss 6. A reference numeral 10 denotes a field magnet adhered to an inner periphery of the rotor frame 8. The motor is rotated as a result of the magnetic repulsion which acts between the field magnet 10 and a driving coil 11 wound around the stator 9.
Reference numeral 12 denotes a fitting oil supplied in order to stabilize the initial lubrication between the end surface of the anti rotor frame side oilless slide bearing 3 and the thrust plate 4; reference numerals 13 and 14 respectively denote an oil thrower for preventing flow of the lubricant from the rotor frame side and a lubricant leakage preventing rubber cap for preventing leakage of the lubricant from the anti rotor frame side; and reference numeral 15 denotes a driving circuit for controlling commutation of the driving coil 11.
The operation of the thus-arranged conventional bearing device will now be described. When the rotor frame 8 and the shaft 1 rotate as a result of the magnetic repulsion which acts between the stator 9 and the field magnet 10, the inner-diameter surfaces of the rotor frame side and anti rotor frame side oilless slide bearings 2 and 3 slide against the outer-diameter surface of the shaft 1, and the end surface of the anti rotor frame side oilless slide bearing 3 slides against the thrust plate 4, thus causing a lubricant to well up due to expansion of and reduction in the viscosity of the lubricant in the oilless slide bearing, caused by the generation of a frictional heat as a result of sliding, and due to the pumping action of the oilless slide bearing itself. In the radial direction, the lubricant which has welled up is pushed into a narrow portion of a gap between the shaft 1 and the inner-diameter surfaces of the rotor frame side and anti rotor frame side oilless slide bearings 2 and 3 in a wedge-like form, generating a pressure in the lubricant. The generated pressure of the lubricant acts on the shaft 1 as a floating force, reducing the frictional resistance between the slide bearings 2 and 3 and the shaft 1. The floating force acts in such a manner that a lubricated condition in which no metal contact occurs is maintained over a long period of time.
In the axial direction, both the oil which has welled up and the fitting oil 12 swirlingly flow in a gap between the end surface of the anti rotor frame side oilless slide bearing 3 and the thrust plate 4, precluding a direct contact therebetween. Thus, a frictional resistance is reduced, and an excellent lubricated condition lasts over a long period of time.
However, in the above-described conventional structure, a force greater than the surface tension of the lubricant present near the thrust plate 4 and the snap ring 5 is exerted by the swirl flow of the lubricant which is generated by the slide of the end surface of the anti rotor frame side oilless slide bearing against the thrust plate 4 in order to axially support thrust load, and the lubricant thereby flows along the inner-diameter surface of the stator boss 6 and reaches as far as the contact between the stator boss 6 and the lubricant leakage preventing rubber cap 14.
If that happens, the lubricant may be absorbed by the rubber cap due to the characteristics of the material thereof. Alternatively, the lubricant whose viscosity has been reduced by the frictional heat may be present in the contact between the lubricant leakage preventing rubber cap 14 and the inner-diameter surface of the stator boss 6. That lubricant present in the contact may flow out to the outside of the motor along the boundary therebetween depending on the magnitude of the contact pressure between the rubber cap 14 and the stator boss 6.
The lubricant which leaks along the boundary may not only flow out to the outside of the motor along the gap between the inner peripheral surface of the stator boss supporting portion and the outer peripheral surface of the lubricant leakage preventing rubber cap, but also penetrate a gap between the stator boss and the stator boss supporting portion, and flows into the motor through the stator.
Such absorption and leakage of the lubricant occur whenever the motor is rotated. Leakage of the lubricant is stopped when the operation of the motor stops by the action of the surface tension of the lubricant and the capillary phenomenon of the oilless slide bearing. Due to the leakage of the lubricant which occurs during the rotation of the motor, the lubricant in the anti rotor frame side oilless slide bearing 3 is consumed greatly. Consumption of the lubricant in the anti rotor frame side oilless slide bearing 3 and the resulting damage to the anti rotor frame side oilless slide bearing 3 induce the damage to the rotor frame side oilless slide bearing 2, even though the oilless slide bearing 2 still contains a sufficient amount of lubricant in it, thus reducing the life of the entire bearing element.
SUMMARY OF THE INVENTION
In view of the aforementioned problems of the conventional art, an object of the present invention is to provide a highly reliable, durable and inexpensive bearing device for a motor which can prevent flow out of a lubricant due to absorption or leakage thereof.
To achieve the above-described object, the present invention provides a bearing device for a motor which comprises an annular oil seal washer, made of a viscoelastic member with at least one adhesive layer provided on surface thereof. The oil seal washer is sandwiched by an end surface of a stator boss and a substantially disk shaped resin cap fixed on an inner peripheral surface of a stator boss supporting portion.
In the thus-arranged bearing device for the motor, when the rotor frame and the shaft rotate due to the magnetic repulsion which acts between the stator and the field magnet and the end surface of the anti rotor frame side oilless slide bearing thereby slides against the thrust plate in order to axially support thrust load, a force exceeding the surface tension of the lubricant near the thrust plate and the snap ring may be exerted due to the swirling flow of the lubricant caused by the sliding, causing the lubricant to flow along the innerdiameter surface of the stator boss to the contact surface between the stator boss and the viscoelastic member with the adhesive layers provided thereon and to the resin cap. However, the lubricant which flows out is absorbed by the viscoelastic member, or the flow of the lubricant is obstructed by both the joined surface between the adhesive layer on one surface of the viscoelastic member and the end surface of the stator boss and the joined surface between the adhesive layer on the other surface of the viscoelastic member and the resin cap, and flow out of the lubricant caused by absorption or leakage thereof can be completely prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of an axial fan motor to which a first embodiment of a bearing device according to the present invention is applied;
FIG. 2 is a cross sectional view showing a second embodiment of the bearing device according to the invention;
FIG. 3 is a bottom view of a resin cap in the second embodiment of the invention;
FIG. 4 is a perspective view showing a third embodiment of the bearing device according to the invention;
FIG. 5 is a cross-section taken along the line V--V of FIG. 4; and
FIG. 6 is a cross sectional view of a conventional bearing device for an axial fan motor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will be described with reference to the accompanying drawings.
FIG. 1 shows an axial fan motor to which a first embodiment of the bearing device for motor according to the present invention is applied. Identical reference numerals in FIG. 1 to those in FIG. 6 represent similar or identical elements.
The bearing device for the axial fan motor, shown in FIG. 1, differs from the conventional device shown in FIG. 6 in that an annular oil seal washer 16 made of a viscoelastic substance (which may be an acrylic resin type foam) having a pressure-sensitive adhesive layer (which may be made of an acrylic adhesive) on each of the two surfaces thereof is used in place of the conventional lubricant leakage preventing rubber cap 14 as means for preventing leakage of the lubricant near the anti rotor frame side oilless slide bearing 3. The oil seal washer 16 is sandwiched by an end surface 17 of the stator boss 6 and an inner surface 19 of a substantially disk-shaped resin cap 18. The resin cap 18 is press fitted into the stator boss supporting portion 7 so that an outer peripheral surface 20 of the resin cap 18 is fixedly pressed against an inner peripheral surface 21 of the stator boss supporting portion 7.
The operation of the bearing device according to the present invention will now be described. In the bearing device for the axial fan motor, having the aforementioned structure, when the rotor frame 8 and the shaft 1 rotate due to the magnetic repulsion which acts between the stator 9 and the field magnet 10 and the end surface of the anti rotor frame side oilless slide bearing 3 thereby slides against the thrust plate 4 in order to axially support thrust load, a force exceeding the surface tension of the lubricant near the thrust plate 4 and the snap ring 5 may be exerted due to the swirling flow of the lubricant caused by the sliding, causing the lubricant to flow along the inner-diameter surface of the stator boss 6 to the contact surface between the stator boss 6 and the viscoelastic member 16 with the adhesive layers and to the resin cap 18. However, the lubricant which flows out is absorbed by the viscoelastic member 16, or the flow of the lubricant is obstructed by both the joined surface between the adhesive layer on one surface of the viscoelastic member 16 and the end surface 17 of the stator boss 6 and the joined surface between the adhesive layer on the other surface of the viscoelastic member 16 and the resin cap 18, and flow out of the lubricant caused by absorption or leakage thereof can be completely prevented.
The end surface 17 of the stator boss, which is generally formed by ultrasonic welding, has convex irregularities, and the oil seal washer 16 is deformable in such a manner that it fits well to the irregular surface of the stator boss because it is made of a viscoelastic substance. As a result, the contact area between the oil seal washer 16 and the stator boss end surface 17 increases, and complete prevention of leakage of the lubricant is thus assured.
Further, since the leakage of the lubricant from the stator boss end surface 17 can be prevented, penetration of the lubricant to the gap between the stator boss 6 and the stator boss supporting portion 7, which would occur in a conventional bearing device, can be prevented, thus preventing flow of the lubricant into the inside of the motor.
Although the oil seal washer 16 has an annular shape in this embodiment in order to prevent contact thereof to the shaft 1, if it is permitted in terms of the axial dimensions, it may have a disk shape. Alternatively, in order to enhance the joining strength between the adhesive layer and the resin cap, the inner surface 19 of the resin cap 19 may be roughened by grain forming to achieve the anchoring effect of the adhesive layer.
If it is possible to firmly grip the viscoelastic member 16 between the stator boss end surface 17 and the resin cap 18, an oil seal washer may have the adhesive layer only on one surface thereof or have no adhesive layer at all.
Other structures of fixing the oil seal washer will now be described with reference to FIGS. 2 through 5.
In the structure shown in FIGS. 2 and 3, the outer peripheral surface of the resin cap 18 is threaded in the axial direction of the shaft 1 to form a male screw 22, and the inner peripheral surface of the stator boss supporting portion 7 is threaded to form a female screw 23 which engages with the male screw 22. The oil seal washer 16 is fixed between the stator boss 6 and the resin cap 18 by the engagement of the male and female screws 22 and 23. In that case, in order to rotate the resin cap 18, a rectangular groove 24 must be formed on the outer surface of the resin cap 18, and the oil seal washer 16 must not have an adhesive layer on the surface thereof which opposes the inner surface 19 of the resin cap 18.
In another oil seal washer fixing structure shown in FIGS. 4 and 5, the inner peripheral surface 21 of the stator boss supporting portion 7 has a plurality of recessed portions 25 (four recessed portions in the illustrated structure), and the outer peripheral surface 20 of the resin cap 18 has a plurality of snap fit type protruding portions 26 which engage with the recessed portions 25. The oil seal washer 16 is fixed between the stator boss end surface 17 and the inner surface 19 of the resin cap 18 by bringing the recessed portions 25 into engagement with the protruding portions 26.
Other oil seal washer fixing structure will also be considered. In a modification of, for example, the structure shown in FIGS. 2 and 3, a plurality of tapered key-form grooves are formed on the inner peripheral surface of the stator boss supporting portion in such a manner that they are connected to the outer end surface of the motor, and a plurality of protrusions, which engage with the key-form grooves, are formed on the outer peripheral surface of the resin cap. The oil seal washer is fixed by turning the resin cap while bringing the protrusions into engagement with the grooves.
As will be understood from the foregoing description, in the present invention, since the annular oil seal washer, made of the viscoelastic member having the adhesive layer on each of the two surfaces thereof, is sandwiched by the stator boss end surface and the substantially disk-like shaped resin cap and the outer peripheral surface of the resin cap is fixedly pressed against the inner peripheral surface of the stator boss supporting portion, it is possible to greatly diminish a reduction in the life of the anti rotor frame side oilless slide bearing caused by the leakage and flow out of the lubricant, which would occur in a conventional oilless slide bearing during the rotation of the motor and thus precludes an increase in the reliability of the motor.
When the consumption of the lubricant in the anti rotor frame side oilless slide bearing is sufficiently improved, a deviation of the conventional lubricant consumption rate can be corrected. Accordingly, the lubricant contained in the oilless slide bearing can be effectively used, and the advantages of the oilless slide bearing, the long life and inexpensiveness, can thus be utilized.
Further, since the oil seal washer made of a viscoelastic substance is used, even if the surface to be sealed by the oil seal washer has a complicated shape, the oil seal washer can fit well to its shape. As a result, a reliable joined state of the oil seal washer can be maintained regardless of the shape of the sealed surface, and flow of the lubricant can thus be completely prevented. | The invention relates to a bearing device for a motor comprising a rotor frame with a field magnet provided on an inner periphery thereof, a shaft coupled to the rotor frame, an oilless bearing for rotatably supporting the shaft, a stator fixedly accommodating the oilless bearing, and a stator fixed to an outer peripheral portion of the stator boss. The bearing device comprises an annular oil seal washer made of a viscoelastic member with an least an adhesive layer provided on a surface thereof, and a substantially disk shaped resin cap. The oil seal washer is sandwiched between an end surface of the stator boss and the resin cap fixed on an inner peripheral surface of a stator boss supporting portion. | 5 |
FIELD OF THE INVENTION
The invention relates to a bacterial cellulose composite with capsules embedded therein and preparation thereof, and more particularly to a composite of calcium alginate capsules encapsulating functional components being discretely embedded in a matrix of Gluconacetobacter xylinus cellulose; the functional components may be drugs, probiotics, or nutrients, such as fungal polysaccharides.
DESCRIPTION OF PRIOR ART
The bacterium Gluconacetobacter xylinus (or used to be called Acetobacter xylinum ) is able to produce white gelatinous bacterial cellulose (BC) by fermentation, which is commonly called Nata or Nata de coco, and possesses high concentration of cellulose, nano-scale structure, and high mechanical strength. Nata de coco is widely applied in foods, and the applications can be divided into three categories including snack foods, functional foods, and food additives. Nata de coco is often used in the snack foods because it not only tastes chewy and smooth, but also has an appealing translucent white appearance. It can also be mixed with a variety of colors and flavors and is highly shapeable, which makes it ideal for applications in products like jellies, canned foods, and beverages. In addition, bacterial cellulose can be cut up, homogenized and used as food additives, because it is found to have high water retention capacity, low viscosity, and is resistant to acid and heat. Therefore, it is often used as emulsifiers, stabilizers, fillers, and texture modifiers in the food additives, and commonly added as melting-resistant agents in ice creams, as flavoring sauces, as emulsifiers in margarine, or as forming agents in vegetarian meats, sausages, or meatballs. In regard to the functional foods, Nata de coco is often used as a dietary fiber therein, because it is not absorbed by the human body and makes people feel full after ingestion, and also increases intestinal tract movements that are beneficial in preventing constipation and colorectal cancers. Hence it is commonly used to develop low-calorie dietary and supplementary foods.
Encapsulation refers to the chemical or physical process of wrapping active components inside of a polymer material, and is important in preserving and providing controlled release of the active components, which subsequently helps deliver the components into the human body timely. The applications, materials, and techniques related to encapsulation have been extensively disclosed before. Microbial polymer matrix encapsulation is a newly developed technology. The hydroxyl polymers of biological substances that are most commonly used for encapsulation are alginate, polyacrylamide, carrageenan, agar, or agarose, in which only alginate and carrageenan can be easily shaped into a sphere along with the encapsulated substances. This is achieved by ionotropic gelling, which is done by dripping sodium alginate into a calcium ion solution, and by dripping carrageenan into a potassium ion solution.
In regard to selecting encapsulation materials, calcium alginate is preferable because it is convenient, non-toxic, has good bio-compatibility, and of low costs (Sheu and Marshall, 1993, J. Food Sci. 54: 557-561). Alginate is a straight-chain heteropolysaccharide derived from the D-mannuronic acid and L-guluronic acid of various algae extracts. The supportive characteristic of alginate is intimately related to the composition and sequence of L-guluronic acid and D-mannuronic acid. Divalent cations like Ca 2+ tend to bind with polymers of L-guluronic acid (Krasaekoopt et al., 2003, Int. Dairy J. 13: 3-13). Moreover, calcium alginate has another advantage in that the diffusion of calcium ions therefrom leads to the dissolution of calcium alginate, which in turn releases the encapsulated microbes into the digestive tract.
Chinese patent CN100460020 C discloses a method for preparing an inter-adhesion film made of multiple layers of Gluconacetobacter xylinus cellulose, which comprises the steps of culturing Gluconacetobacter xylinus in a liquid medium statically for 6-10 days to form a superficial film; adding a culturing liquid slowly on top of the film by using a dripping tube; repeating the slow addition of the culturing liquid every 5-6 days until the film reaches an average thickness of 3-8 mm. The multiple-layer bacterial cellulose film can then be used as a medical dressing.
Though the general encapsulation materials like sodium alginate, carrageenan, and agar are good for enclosing functional components, they are disadvantaged in having softer texture and thus easily damaged in following processing steps, which consequently harms the quality and quantity of the final products. Moreover, the encapsulated products often have capsule walls damaged from chewing or digestion, which causes the enclosed functional components to leak out prematurely.
As far as the inventors of this invention knows, a composite made from combining cellulose and capsules has not been developed until now, and the inventors have firstly prepare a bacterial cellulose composite having capsules embedded therein, so as to reduce the occurrence of capsule walls damaged by external forces.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide a bacterial cellulose composite having capsules embedded therein, which comprises a bacterial cellulose matrix and a plurality of capsules being discretely embedded in said matrix, wherein said capsules include a core functional component and bio-degradable polymeric shells for enclosing said functional component.
Another objective of the invention is to provide a method for preparing a bacterial cellulose composite having capsules embedded therein, comprising:
providing a plurality of capsules, wherein said capsule includes a core functional component and a bio-degradable polymeric shell for enclosing said functional component;
providing a reaction tank and a sheet-like bacterial cellulose therein, wherein said sheet-like bacterial cellulose has a thickness of 2-10mm;
discretely placing the plurality of capsules on a top surface of said sheet-like bacterial cellulose, and then adding a liquid medium inoculated with bacteria on said top surface; or adding a liquid medium inoculated with bacteria on said top surface first, then discretely placing the plurality of capsules thereon, wherein the liquid medium inoculated with bacteria is allowed to immerse said sheet-like bacterial cellulose, and a liquid surface thereof is 0.2-0.8 mm above the top surface of said sheet-like bacterial cellulose;
culturing the bacteria statically and under atmospheric condition for a period of time, thereby allowing new bacterial cellulose to form at an interface where a liquid surface of the medium is in contact with the atmosphere, and the newly formed bacterial cellulose is adhered to the top surface of the sheet-like bacterial cellulose;
adding a liquid medium on top of the newly formed bacterial cellulose, and culturing the bacteria statically and under atmospheric condition for a period of time, thereby allowing another new bacterial cellulose to form at an interface where a liquid surface of the medium is in contact with the atmosphere, and the another newly formed bacterial cellulose is adhered to a top surface of the newly formed bacterial cellulose sheet-like bacterial cellulose thereunder, and repeating this step until the plurality of capsules are embedded in a matrix of bacterial cellulose formed from the sheet-like and newly formed bacterial cellulose.
The bacterial cellulose is preferably Gluconacetobacter xylinus cellulose.
The bio-degradable polymer is preferably calcium alginate, carrageenan, agar, agarose, or polyacrylamide. The bio-degradable polymer is more preferably calcium alginate.
The functional component is preferably a drug, probiotic, or nutrient.
The functional component is more preferably fungal polysaccharide, such as Ganoderma lucidum polysaccharide, Antrodia camphorata polysaccharide, Coriolus versicolor polysaccharide, or a mixture thereof.
The capsules are preferably 1-10 mm in diameter.
Preferably in the preparation method of the invention, the sheet-like bacterial cellulose is 3-5 mm in thickness, the capsules are 2-3 mm in diameter, and a liquid surface of the liquid medium inoculated with bacteria is 0.5 mm above the top surface of the sheet-like bacterial cellulose.
The preparation method of the invention also preferably comprises the following steps for preparing the plurality of capsules:
mixing a sodium alginate solution with a solution of fungal polysaccharide to obtain a mixed solution, wherein the concentration of fungal polysaccharide and sodium alginate in the mixed solution is 0.06-0.15% and 1.0-2.5%, respectively;
adding said mixed solution quantitatively into a calcium chloride solution, wherein the concentration of calcium chloride solution is 2.0-5.0%; and
continuing to stir the solution for a period of time to result in capsules of fungal polysaccharides.
In the preparation method of the invention, the liquid medium added onto the newly and the another newly formed bacterial cellulose is preferably at a rate of 2.1×10 −3 to 5.4×10 −3 mL/cm 2 ·hr.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Although the techniques for using alginate to enclose functional components and statically culture Gluconacetobacter xylinus cellulose are both already known in the industry, a composite made from both had not been successfully attempted until a disclosure is made in this invention. Relevant embodiments and comparisons are used to illustrate the problems encountered by the inventor in attempting to prepare a bacterial cellulose composite with capsules embedded therein, and the corresponding solutions.
Preparation 1: The Preparation of Capsules
The aqueous solutions of polysaccharides, sodium alginate, and CaCl 2 were firstly subjected to autoclaving for sterilization, and then used to prepare capsules under sterile conditions according to the following steps.
Mixed the aqueous solutions of polysaccharides (the concentration is 0.9%) and sodium alginate (the concentration is 5%) together and stirred evenly, took caution to prevent bubbles from forming. Added the mixed solution drop-by-drop into a stirring aqueous solution of 100 mL 5% CaCl 2 by using a syringe or dripping tube, and continued to slowly stir the solution for 5 minutes after the addition to allow it to solidify. The prepared capsules (with a diameter of 2-3 mm) were then washed with sterile water and stored away for later use.
Preparation 2: The Cultivation of Gluconacetobacter xylinus and the Preparation of Sheet-Like Gluconacetobacter xylinus Cellulose
YE medium
Sucrose
50 g/L
Enzyme extracts
5 g/L
(NH 4 ) 2 SO 4
5 g/L
KH 2 PO 4
3 g/L
MgSO 4 •7H 2 O
0.05 g/L
Took the strain of Gluconacetobacter xylinus preserved in a glycerol stock frozen at -80° C., and allowed it to be activated and cultured on a liquid medium at 30° C., so as to obtain a bacterial liquid of activated Gluconacetobacter xylinus.
Transferred 5% of the bacterial liquid of activated Gluconacetobacter xylinus to the YE medium by using a sterile pipette, then statically cultured the bacteria at room temperature for several days, until sheet-like Gluconacetobacter xylinus cellulose having a thickness of 3-5 mm was obtained. Subjected the cultured bacterial cellulose that was mixed with culture medium to filtration, so as to separate solids therein from the liquid medium; this was followed by immersing the solids with deionized water, and then stirring and centrifuging the resulted mixture. Replaced the deionized water until the color of the medium was completely removed, then centrifuged and dehydrated the mixture before immersing it in 1.0% NaOH solution, and boiling for 30 minutes to remove Gluconacetobacter xylinus . Subsequently, allowed the solution to cool, and then centrifuged again to remove the alkaline solution. Repeatedly washed the bacterial cellulose with deionized water until the pH turned neutral and ready for later use (George et al., 2005). In addition to cultivation by oneself, said sheet-like bacterial cellulose can also be purchased commercially.
Comparison 1: Directly Generating Gluconacetobacter xylinus Cellulose on the Culture Medium Having Capsules
Sufficiently mixed a 0.9% polysaccharide solution with a 5% sodium alginate solution at different ratios to prepare capsules; obtained and placed 5 g of capsules in a flask with 10 mL of the YE medium, followed by inoculation with an inoculum size of 10% and static cultivation at 30° C. The addition of polysaccharides did not affect the growth of bacterial cellulose by Gluconacetobacter xylinus . After cultivation for 7 days, surfaces of the capsules were covered with a film of bacterial cellulose, but the bacterial cellulose film formed at the interface where the YE medium was in contact with the atmosphere did not adhere to said surfaces of the capsules, and was easily separated therefrom. When measuring the humid weight and gross polysaccharide concentration in the samples (Dubois et al., 1956), it was found that when polysaccharides were mixed with 5% sodium alginate solution at a volume ratio between 1:1 - 1:4, in order to prepare a bacterial cellulose with polysaccharide capsules dispersed therein, the resulted dry samples contained 0.4403, 0.3514, 0.2727, and 0.2696 g/L of gross polysaccharide concentration, respectively. In comparison with the samples prepared by directly adding the polysaccharide solution during the static culture of bacterial cellulose in the YE medium, the polysaccharide concentration in the bacterial cellulose with polysaccharide capsules dispersed therein was significantly increased.
Comparison 2: Preparing Bacterial Cellulose Composite Having Capsules in a Liquid Medium with Gluconacetobacter xylinus Cellulose Films
After inoculating 10 mL of YE medium with the bacteria and culturing for 3-5 days, a layer of thin cellulose film (approximately 1 mm in thickness) formed superficially. Subsequently, capsules were placed thereinto and new YE medium was added for further culturing. But the weight of the added capsules forced the superficial cellulose film down below the liquid surface, while the newly added medium allowed new cellulose films to be formed at the air-liquid interface, which caused the cellulose films to become divided, and impeded the adhesion between the cellulose and the capsules.
Embodiment 1: Preparing Bacterial Cellulose Composite Having Capsules on Sheet-Like Gluconacetobacter xylinus Cellulose
Firstly placed sheet-like bacterial cellulose (with a thickness of 5 mm and a surface area of 38.5 cm 2 ) at the bottom of a flask, then added the YE medium that has been inoculated with Gluconacetobacter xylinus , ensured that the liquid surface of the medium is 0.5 mm above the top surface of the sheet-like bacterial cellulose before evenly placing 5g of capsules thereon. Statically cultured the sample at 30° C., and Gluconacetobacter xylinus then formed new bacterial cellulose at the air-liquid interface, which was adhered to the sheet-like bacterial cellulose underneath. Consequently, the liquid medium was added at fixed quantity in batch operation, which ensured that 2 mL of YE medium was added in drops every 24 hours to allow for further static culturing. The new bacterial cellulose then formed downwards, and completely enclosed the polysaccharide capsules after about 7 days of culturing; the total thickness of the bacterial cellulose composite increased to approximately 10-12 mm, and the polysaccharide concentration in the bacterial cellulose composite could reach 6.92%.
Embodiment 2: Effects of Sterilization Treatment to the Thermal Stability of Bacterial Cellulose Composites
The final products of Embodiment 1 were subjected to sterilization treatment, which meant they were heated for sterilization at 121° C. in a steam autoclave for 15 minutes. After sterilization, the loss rates of functional components in bacterial cellulose composites having different thicknesses, and of different starting amounts of polysaccharide capsules were examined. It was revealed that when sheet-like bacterial cellulose with a thickness of 3 mm was used for the preparation, the total loss of polysaccharides for the resulted products of bacterial cellulose composite was 3.70% after sterilization. Whereas when sheet-like bacterial cellulose with a thickness of 8 mm was used for the preparation, the total loss of polysaccharides for the resulted products of bacterial cellulose composite was 0.02% after sterilization. After sterilization, the products of bacterial cellulose composite only appeared to have culturing medium released superficially and lighter in color, and the overall form and shape of the polysaccharide capsules were not changed significantly after the high-temperature and high-pressure sterilization. In addition, when 3 mm-thick sheet-like Gluconacetobacter xylinus cellulose and 10 g of polysaccharide capsules were used to prepare bacterial cellulose composites according to the method of Embodiment 1, the total loss of polysaccharides for the resulted products under the same sterilization conditions (heated at 121° C. for 15 minutes) was 1.23%.
The embodiments of the invention had showed that the method disclosed herein effectively increases the adhesion between polysaccharide capsules and bacterial cellulose. Moreover, the nano structure of the outer bacterial cellulose serves as a protective material for the polysaccharide capsules therein, which reduces possible damage to the polysaccharide capsules from the follow-up treatments, thereby effectively preserving the concentration of functional components in the products of bacterial cellulose composites.
In other experiments, the inventors also found that the bacterial cellulose composites with polysaccharide capsules prepared according to Embodiment 1 can inhibit the activeness of α-glucosidase, and the inhibition of α-glucosidase is positively related to the total polysaccharide concentration thereof. For example, if the total polysaccharide concentration of a product of bacterial cellulose composites is 2.70%, the α-glucosidase inhibition rate will reach 17.8%; if the total polysaccharide concentration is 4.40%, the inhibition rate will be 41.4%, and if the total polysaccharide concentration is 6.49%, the inhibition rate will reach 61.9%. Similar effects can also be achieved by using a single product of the bacterial cellulose composite with a fixed total polysaccharide concentration, but the amount of the composite product has to be modified in order to adjust its level of inhibition on α-glucosidase.
The preferred embodiments of the invention described above are meant to illustrate the invention, and are not to be used to limit the scope of the invention; those skilled in the art should be able to make modifications and changes to the embodiments without departing from the scope of the invention. | A composite of bacterial cellulose and capsules embedded therein is prepared, for example calcium alginate capsules encapsulating functional components being discretely embedded in a matrix of Gluconacetobacter xylinus cellulose. The functional components may be drugs, probiotics or nutrients, such as fungal polysaccharide. | 0 |
RELATED APPLICATIONS
This application is a Divisional of, commonly-invented, and commonly-assigned U.S. patent application Ser. No. 12/512,222 (now U.S. Pat. No. 8,730,764) filed Jul. 30, 2009 and entitled Telemetry Coding and Surface Detection for a Mud Pulser, the contents of which are hereby incorporated for all purposes.
FIELD OF THE INVENTION
The present invention relates generally to data communication between a downhole tool deployed in a subterranean borehole and surface instrumentation. More particularly, this invention relates to downhole telemetry coding and surface detection and decoding of mud pulse telemetry.
BACKGROUND
Typical petroleum drilling operations employ a number of techniques to gather information about the borehole and the formation through which it is drilled. Such techniques are commonly referred to in the art as measurement while drilling (MWD) and logging while drilling (LWD). As used in the art, there is not always a clear distinction between the terms LWD and MWD. Generally speaking MWD typically refers to measurements taken for the purpose of drilling the well (e.g., navigation) and often includes information about the size, shape, and direction of the borehole. LWD typically refers to measurement taken for the purpose of analysis of the formation and surrounding borehole conditions and often includes various formation properties, such as acoustic velocity, density, and resistivity. It will be understood that the present invention is relevant to both MWD and LWD operations. As such they will be referred to commonly herein as “MWD/LWD.”
Transmission of data from a downhole tool to the surface is a difficulty common to MWD/LWD operations. Mud pulse telemetry is one technique that is commonly utilized for such data transmissions. During a typical drilling operation, drilling fluid (commonly referred to as “mud” in the art) is pumped downward through the drill pipe, MWD/LWD tools, and the bottom hole assembly (BHA) where it emerges at or near the drill bit at the bottom of the borehole. The mud serves several purposes, including cooling and lubricating the drill bit, clearing cuttings away from the drill bit and transporting them to the surface, and stabilizing and sealing the formation(s) through which the borehole traverses. In a typical mud pulse telemetry operation, a transmission device, such as an electromechanical pulser or a mud siren located near the drill bit generates a series of pressure pulses (in which the data is encoded) that is transmitted through the mud column to the surface. At the surface, one or more transducers convert the pressure pulses to electrical signals, which are then transmitted to a signal processor. The signal processor then decodes the signals to provide the transmitted data to the drilling operator.
One significant difficulty with decoding a mud pulse signal is the poor signal to noise ratio that results from both low signal amplitude and high noise content. For example, the amplitude of a transmitted pressure pulse tends to attenuate as it travels up the drill pipe. Such attenuation is dependent on many factors including the depth of the borehole, the type of drilling mud, the hydrostatic pressure, the number of joints in the drill string, and the width of the pressure pulse. Moreover, there are a number of potential sources of noise generated during drilling operations including turning of the drill bit and/or drill pipe in the borehole, sliding and/or impact of the drill pipe against the borehole wall, and the mud pump that is used to pump the mud downhole.
Due in part to the poor signal to noise ratio, data transmission rates are slow (e.g., on the order of about 1 bit per second). Increasing the transmission rate tends to decrease the signal to noise ratio due to decreased signal amplitude. The low signal to noise ratio also tends to increase the frequency of transmission errors which can erode the reliability of the communication channel and disrupt the synchronization between the downhole encoder and the surface decoder. As is known to those of ordinary skill in the art, these problems can be severe in ordinary drilling operations, and in particular in deep wells.
U.S. Pat. No. 4,908,804 to Rorden discloses a combinatorial coding technique for mud pulse telemetry. While the methods disclosed in the Rorden patent have been commercially utilized, there remains room for further improvement. For example, there remains a need for coding and decoding methodologies that improve both the efficiency and reliability of mud pulse telemetry communications.
SUMMARY
The present invention addresses one or more of the above-described drawbacks of prior art data compression and communication techniques. Aspects of this invention include a method for encoding a non-negative integer. The integer may represent various downhole data, for example, including MWD/LWD data. The method includes encoding at least a portion of the integer using at least one novel Fibonacci derived sequence. The remainder of the integer may be encoded using conventional Fibonacci encoding. Surface detection and decoding methodologies are also disclosed.
Exemplary embodiments of the present invention may advantageously provide several technical advantages. For example, exemplary methods according to this invention tend to improve the encoding efficiency of large non-negative integers commonly utilized to represent downhole data. As such, the invention also tends to improve communication speed. Embodiments of the invention also tend to improve synchronization between the downhole and the surface locations, e.g., by the use of predefined word and window tags as described in more detail below. The inventive coding methodology also tends to result in coded bit sequences having sparsely spaced 1's. This advantageously facilitates pulse detection in MWD/LWD embodiments by reducing inter-pulse/inter-symbol interference. Downhole power savings may also be realized.
In one aspect the present invention includes a method for encoding a non-negative integer. After acquiring the integer, the method includes encoding at least a portion of the integer using at least a first order Fibonacci derived sequence to obtain a first encoded portion and encoding an uncoded remainder of the integer using a zero-th order Fibonacci sequence to obtain a second encoded portion. The method further includes combining the first encoded portion and the second encoded portion to obtain an encoded integer.
In another aspect, the present invention includes a method for transmitting downhole data to a surface location. The method includes acquiring a non-negative integer representative of the downhole data. At least a portion of the integer is then encoded using at least a first order Fibonacci derived sequence to obtain a first encoded portion. An uncoded remainder of the integer is encoded using a zero-th order Fibonacci sequence to obtain a second encoded portion. The first and second encoded portions are then combined to obtain an encoded integer, which is then transmitted to the surface.
In a further aspect, the present invention includes a method for receiving an encoded integer. The method comprises acquiring a digitized waveform including a first plurality of pulses distributed among a second plurality of time slots and locating each of the pulses in the digitized waveform. At least one confidence value is computed for each of the pulses. The method further includes selecting a subset of the plurality of pulses having low confidence values and generating a set of unique waveforms corresponding to various combinations of the selected subset of pulses. A cross-correlation between the acquired digitized waveform and each of the generated waveforms is then computed. The waveform having the highest cross-correlation is then selected for decoding.
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 by those skilled in the art that the conception and the 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 by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 depicts a conventional drilling rig on which exemplary embodiments of the present invention may be utilized.
FIG. 2 depicts a conventional mud flow arrangement in which exemplary embodiments of the present invention may be utilized.
FIG. 3 depicts a flowchart of one exemplary data encoding embodiment in accordance with the present invention.
FIG. 4 depicts an exemplary code matrix in accordance with the present invention including the conventional Fibonacci sequence and first through seventh order Fibonacci derived sequences.
FIG. 5 depicts a flowchart of one exemplary embodiment of a surface detection methodology in accordance with the present invention.
FIG. 6 depicts a flowchart of one exemplary embodiment of a matched filtering methodology in accordance with the present invention.
FIG. 7 depicts a flowchart of a selective matched filtering methodology in accordance with the present invention.
DETAILED DESCRIPTION
FIG. 1 depicts an exemplary offshore drilling assembly, generally denoted 10 , suitable for employing exemplary method embodiments in accordance with the present invention. In FIG. 1 a semisubmersible drilling platform 12 is positioned over an oil or gas formation (not shown) disposed below the sea floor 16 . A subsea conduit 18 extends from deck 20 of platform 12 to a wellhead installation 22 . The platform may include a derrick and a hoisting apparatus for raising and lowering the drill string 30 , which, as shown, extends into borehole 40 and includes drill bit 32 , a transmission device 50 (e.g., a conventional electromechanical pulser), and at least one MWD/LWD tool 60 . Drill string 30 may optionally further include substantially any number of other tools including, for example, other MWD/LWD tools, stabilizers, a rotary steerable tool, and a downhole drilling motor.
It will be understood by those of ordinary skill in the art that the deployment illustrated on FIG. 1 is merely exemplary. It will be further understood that exemplary embodiments in accordance with the present invention are not limited to use with a semisubmersible platform 12 as illustrated on FIG. 1 . The invention is equally well suited for use with any kind of subterranean drilling operation, either offshore or onshore. Moreover, it will further be appreciated that the invention is not limited mud-pulse telemetry operations or even to downhole applications.
Referring now to FIG. 2 , an exemplary prior art mud pulse telemetry apparatus 80 is illustrated. A mud pump 81 generates a downward traveling mud flow 83 into a standpipe 95 and down through drill string 30 . Rotation of the drill string (and/or drill bit 32 ) creates borehole 40 in the earth (or in sea floor 16 as shown on FIG. 1 ). The mud flow 83 emerges at or near the drill bit 32 and creates an upward traveling mud flow 84 through annulus 46 (the space between the drill string 30 and the borehole wall). Conventional rigs commonly further include a pulsation dampener 90 (also referred to in the art as a desurger) that evens out the flow 83 in the standpipe 95 and drill string 30 . The pulsation dampener 90 essentially acts like an accumulator to smooth outlet pressure generated by the mud pump 81 .
MWD/LWD data is encoded downhole (e.g., via a conventional downhole controller). A transmission device 50 , such as a conventional electromechanical mud pulser, produces an acoustic pressure wave 85 (a “waveform” that includes the encoded data). This pressure wave 85 travels towards the surface at approximately the speed of sound (typically in the range of about 2000 to 4000 feet per second) through the downward traveling mud 83 . It will be appreciated that the signal may also be transmitted through and received from the upward traveling mud flow 84 in the annulus 46 .
The transmitted pressure wave 85 may be received (detected) at transducer 87 and decoded and analyzed via signal processor 89 (for example a conventional data acquisition computer or DSP board). Substantially any suitable transducer arrangement may be utilized. For example, the use of a single transducer, as depicted on FIG. 2 is common in the art. Multiple transducer arrangements are also known, for example, as disclosed in U.S. Pat. No. 6,421,298 to Beattie et al. A differential transducer arrangement may also be utilized. One such suitable arrangement is disclosed in commonly assigned U.S. Pat. No. 7,489,591 to Mumby.
Methods in accordance with the present invention pertain to downhole encoding and surface decoding of the MWD/LWD data. Methods in accordance with the present invention also relate to windowing methodology for synchronizing the downhole encoder with the surface decoder and a matched filtering detection scheme for reconstructing the transmitted bit sequence. These methods are described in more detail below under appropriate headings.
Turning now to FIG. 3 , one exemplary embodiment of an encoding methodology 100 in accordance with the present invention is depicted in flow chart form. At 102 , a non-negative integer suitable for encoding is received. At 104 at least a portion of the non-negative integer is encoded using one or more novel higher order Fibonacci derived sequences. These novel Fibonacci derived sequences are described in more detail below with respect to FIG. 4 . A remainder of the non-negative integer is encoded using a conventional (zero-th order) Fibonacci sequence at 106 . The encoded bit stream may optionally be denormalized at 108 prior to transmission.
Fibonacci Encoding and Decoding
As described above with respect to FIG. 3 , encoding schemes in accordance with the present invention make use of both the conventional Fibonacci sequence and novel Fibonacci derived sequences. The first 19 elements of certain of these sequences are depicted on FIG. 4 , with column F 0 depicting the conventional Fibonacci sequence (which may be thought of as a zero-th order Fibonacci derived sequence) and columns F 1 through F 7 depicting first through seventh order Fibonacci derived sequences. As is known to those of skill in the mathematical arts, the conventional Fibonacci sequence may be represented mathematically as follows:
F 0 ( i )= F 0 ( i− 1)+ F 0 ( i− 2) Equation 1
where F 0 (i) represents the i-th element of the Fibonacci sequence such that i≧3 and F 0 (1)=1 and F 0 (2)=2. The novel Fibonacci derived sequences may be represented mathematically as follows:
F k ( j )= F k ( j− 1)+ F k−1 ( j ) Equation 2
where F k (j) represents the j-th element of the k-th order Fibonacci derived sequence such that j≧2 and k≧1 and F k (1)=1. As is evident from Equation 2, the higher order Fibonacci derived sequences may be thought of as being derived from the conventional Fibonacci sequence. For example, the first order Fibonacci derived sequence may be derived from the conventional Fibonacci sequence (the zero-th order sequence). The second order Fibonacci derived sequence may be derived from the first order sequence (which may be derived from the conventional sequence). And so on.
The Fibonacci derived sequences may be represented in alternative mathematical form as follows:
F k ( j )= F k ( j− 1)+ F k ( j− 2)+2; k= 1
F k ( j )= F k ( j− 1)+ F k ( j− 2)+ B k−1 ( j ); k> 1 Equation 3
where B represents an auxiliary arithmetic sequence given as follows
B
1
B
2
B
3
B
4
B
5
…
1
1
1
1
1
3
4
5
6
7
5
9
14
20
27
7
16
30
50
77
9
25
55
105
182
⋮
⋱
Equation
4
where column B 1 is an arithmetic sequence with constant 2 of order 1. Column B 2 may be thought of as being an arithmetic sequence with constant 2 of order 2, since B 2 (j)−B 2 (j−1)=B 1 (j). Column B 3 may be thought of as being an arithmetic sequence with constant 2 of order 3 since B 3 (j)−B 3 (j−1)=B 2 (j). And so on.
The above defined Fibonacci sequence and Fibonacci derived sequences may be advantageously used in accordance with the present invention to encode any non-negative integer. Those of skill in the mathematical and signal processing arts will recognize that any non-negative integer x may be encoded using the conventional Fibonacci sequence (i.e., column F 0 in FIG. 4 ). Zeckendorf's theorem states that every positive integer can be represented in a unique way as the sum of one or more distinct Fibonacci numbers in such a way that the sum does not include any two consecutive Fibonacci numbers. A suitable algorithm for such Fibonacci encoding may be given in Algorithm I as follows:
Step (1): Initialize F 0 (x) to 0.
Step (2): Search F 0 for the biggest element smaller than x (the i-th element where i=0 for x=0) and then set the (i+2)-th bit and the (i+1)-th bit of F 0 (x) to 1. Also, set x=x−F 0 (i).
Step (3): Repeat the following steps until x=0: (a) search F 0 for the biggest element smaller than x (the j-th element), (b) set the (j+1)-th bit of F 0 (x) to 1, and (c) set x=x−F 0 (j).
Step (4): Output bits from the least significant bit (LSB) to the most significant bit (MSB) of the encoded value.
Such Fibonacci encoding is advantageous in that any non-negative integer may be encoded without the use of consecutive 1s. As a result, the string ‘11’ only appears at the end of an encoded integer and therefore serves as a separator between two consecutively encoded integers. To decode a bit sequence generated by Algorithm I, a controller merely searches for the next ‘11’ and decodes the bit stream between consecutive ‘11’ strings.
While conventional Fibonacci encoding may provide for self-synchronization, it tends to be somewhat inefficient in encoding the large integer values that are commonly utilized to encode various MWD/LWD data. Given the severe bandwidth constraints of conventional mud pulse telemetry, efficiency improvements are desired.
Non-negative integers (particularly large integers) may be more efficiently encoded in accordance with the present invention using the Fibonacci derived sequences (i.e., the higher order Fibonacci sequences described above) while still retaining the advantages of Fibonacci encoding. A suitable algorithm, in accordance with the present invention, for such derived Fibonacci encoding (also referred to herein as higher order Fibonacci encoding) may be given in Algorithm II as follows:
Step (1): Initialize F n (x) to 0.
Step (2): Execute the following steps iteratively from F n to F 1 : (a) search in F k (1≦k≦n) for the biggest element smaller than x (the k i -th element where k i =0 for x=0), (b) set the (k i +k+2)-th bit of F n (x) to 1, and (c) set x=x−F k (k i ).
Step (3): Apply Algorithm 1 to the remainder of x after the completion of Step 2 and set these k 1 +2 least significant bits of F n (x) . Note that this step is performed even when the remainder of x is zero after Step (2).
Step (4): Output bits from the LSB to the MSB of the encoded value.
The above-described derived Fibonacci encoding method in accordance with the present invention may be utilized to encode any non-negative integer for any given order: n≧1. Moreover, such derived Fibonacci encoding retains the self-synchronization feature of conventional Fibonacci encoding in which each integer is identified by the string ‘11’. However, unlike conventional Fibonacci encoding, the string ‘11’ is located in the middle of the encoded integer, between a first portion of the integer that is encoded in Step (2) and a second portion of the integer encoded in Step (3).
With reference again to FIGS. 3 and 4 , this coding methodology is now described in more detail by way of example. The Fibonacci derived sequences may be thought of as being a code matrix in which each higher order sequence F k (0≦k≦n) represents a single column in the matrix. The encoding process begins at a predetermined F n (e.g., n=4 and n=7 in the examples that follow) and proceeds from right to left selecting exactly one value of F k (k i ) from each column. A ‘1’ is recorded in the (k i +k+2)-th bit of F n (x) for each selected F k (k i ). Upon reaching column F 0 , the remainder of x is encoded using Algorithm I. Using this methodology, the positive integer 194,559 is now encoded, first for n=4 and then for n=7.
When n=4, the value 193,015 is selected from column F 4 (row 18 ), the value 1424 is selected from column F 3 (row 10 ), the value 72 is selected from column F 2 (row 6 ), and the value 32 is selected from column F 1 (row 6 ), leaving a remainder of 16. This results in the following bit stream: ‘1000000001000011’ for columns F 4 through F 1 . The remaining 16 may then be encoded as ‘11001000’ via conventional Fibonacci encoding (selecting the values of 13 and 3 in rows 6 and 3 of column F 0 ). Combining the results from columns F 4 through F 1 and column F 0 yields: ‘100000000100001111001000’. In this example, the integer 194,559 is encoded using seven pulses distributed among 24 bits.
When n=7, the value 109,357 is selected from column F 7 (row 12 ), the value 50,779 is selected from column F 6 (row 12 ), the value 22,596 is selected from column F 5 (row 12 ), the value 9,638 is selected from column F 4 (row 12 ), the value 1424 is selected from column F 3 (row 10 ), the value 585 is selected from column F 2 (row 10 ), the value 142 is selected from column F 1 (row 9 ), leaving a remainder of 38. This results in the following bit stream: ‘1111001101’ for columns F 7 through F 1 . The remaining 38 may then be encoded as ‘1100001010’ via conventional Fibonacci encoding (selecting the values of 34, 3, and 1 in rows 8 , 3 , and 1 of column F 0 ). Combining the results from columns F 7 through F 1 and column F 0 yields: ‘111100110101100001010’. Note that a single ‘0’ was introduced between these results since the value selected in F 1 (142) is one row below the highest value selected in F 0 (row 9 vs. row 8 ). In this example, the integer 194,559 is encoded using eleven pulses distributed among 21 bits.
When encoded using conventional Fibonacci encoding, the integer 194,559 requires ten pulses distributed among 27 bits (‘110101010010100010010010000’). The above examples illustrate potential efficiency improvements that may be realized using the derived Fibonacci encoding scheme of the present invention. In this example a savings of 6 bits was realized when n=7 at the expense of only one additional pulse. A savings of 3 bits and 3 pulses was realized when n=4. These pulse savings can significantly improve efficiency depending upon the particular de-normalization scheme utilized (as described in more detail below) and accuracy (depending on the particular surface detection algorithm utilized). A pulse savings also tends to save energy downhole at the MOP (in mud pulse telemetry embodiments). In practice, the use of higher order derived Fibonacci sequences (e.g., n=7 as opposed to n=4) often enables an integer (particular a large integer) to be encoded using fewer bits, however, the use of fewer bits sometimes comes at the expense of requiring additional pulses (as illustrated in the example given above). It will thus be appreciated that there is often a tradeoff between reducing the number of required bits versus reducing the number of required pulses when selecting a particular coding matrix via changing the allowable Fibonacci derived sequence order (note that, for an order n, the coding matrix is unique). It will also be appreciated that the invention is not limited to the use of a coding matrix having any particular number of columns or any particular number of higher order Fibonacci derived sequences. In practice, the coding matrix may be pre-selected so as to optimize efficiency for a given set (or range) of non-negative integers.
Non-negative integers encoded using the methodology described above in Algorithm II may be readily decoded. A suitable methodology for such derived Fibonacci decoding may be given in Algorithm III as follows:
Step (1): Search for the first ‘11’
Step (2): Initialize x to 0.
Step (3): Record the positions of each of the n ‘1’ bits after the first ‘11’. Then decode for the value of each ‘1’ using the corresponding F k (1≦k≦n) and add values to x.
Step (4): Remove the second ‘1’ from the first ‘11’ and record the positions of each ‘1’ before the first ‘11’ (including the first ‘1’ in the first ‘11’). Then decode for the value of each ‘1’ using F 0 and add values to x.
Step (5): Search for next ‘11’ to decode successive integers and repeat steps (2), (3), and (4).
Note that the number of bits used to encode any given non-negative integer is unknown at the decoder prior to decoding. Note also that the number of ‘1’ bits between the ‘11’ identifier in successively encoded integers must be greater than or equal to n. This is guaranteed by the encoding methodology.
By way of example, the previously encoded integer 194,559, encoded above using n=4 higher order Fibonacci derived sequences, is now decoded using Algorithm III. At step (1), the first ‘11’ is identified (moving from right to left), as underlined in the encoded bit stream: ‘1000000001000011 11 001000’. Each of the (n=4) ‘1’ bits following the ‘11’ identifier is assigned a value in step (3) based on its position after (to the left of) the underlined ‘11’. These values are then added to x. The values added to x in this example are 193,015 (selected from column F 4 ), 1424 (F 3 ), 72 (F 2 ), and 32 (F 1 ). At step (4), the string ‘1001000’ (which remains after the second ‘1’ is dropped from the underlined ‘11’) is decoded using F 0 and the appropriate value (16) is added to x. The resultant integer is 194,559.
In order to output a bit sequence generated by Algorithm II to the telemetry channel (the column of drilling fluid), a pressure pulse or a specifically modulated waveform may be generated for each ‘1’ in the bit sequence. Each ‘0’ may be represented by an idle time slot of predetermined duration or a differently modulated waveform. In practical applications, pulses are advantageously separated in time by a sufficiently long duration to accommodate the extremely noise communication channel, (or for bits going through a modulation scheme, bit symbols can be advantageously separated by the difference of phase (and/or amplitude, frequency) offsets in a continuous waveform). Such separation may optionally be accomplished by a denormalization process (step 108 in FIG. 3 ) in which additional slots (or 0's) are added between pulses. For example, when using a mud operated pulser, the following denormalization process may be advantageously utilized in combination with Algorithm II.
In this example, Q represents the number of idle slots used to separate two consecutive pulses. As described above, the coded bit sequence generated by Algorithm II includes first and second coded portions that come after (to the left of) and before (to the right of) the ‘11’ identifier. Each portion includes at least one pulse (at least one ‘1’). Since the ‘1’ bits in the second portion (encoded using F 0 ) are already separated by at least one idle slot (at least one ‘0’), it is sufficient to insert Q−1 idle slots either before or after each pulse. In the first portion (encoded using F k ), the ‘1’ bits are not necessarily separated, so Q idle slots may be inserted either before or after each pulse. The two ‘1’ bits in the ‘11’ identifier may be separated by Q−1 idle slots so as to create a unique (and therefore recognizable) pattern. In one advantageous implementation a word tag (the denormalized ‘11’ identifier) may be defined as being 3Q−1 denormalized slots: Q−1 idle slots between the pulses in the ‘11’ pattern and Q−1 leading idle slots and Q−1 trailing idle slots. In practice this word tag is often easier to identify during surface detection than an individual pulse (e.g., using a matched filtering algorithm as described in more detail below). A suitable denormalization process may be given in Algorithm IV as follows:
Step (1): Convert a bit sequence to a normalized slot sequence by a one-to-one mapping in which ‘1’ is a pulse slot and ‘0’ is an idle slot.
Step (2): Insert Q−1 idle slots immediately before each ‘1’ before ‘11’.
Step (3): Insert Q−1 idle slots immediately before and immediately after the first ‘1’ in ‘11’.
Step (4): Insert Q idle slots immediately before each of the ‘1’ slots (those after ‘11’). After step (4), the output is ready for pulsing.
By way of example, the previously encoded integer 194,559, encoded above using n=4 higher order Fibonacci derived sequences, is now denormalized using Algorithm IV. In this example a denormalization constant Q=3 is used. The invention is, of course, not limited to the use of any particular denormalization constant or even to the use of denormalization. At step (2) Q−1 idle slots are inserted as indicated (the inserted slots are underlined): ‘100000000100001111001 00 000’. At step (3) Q−1 idle slots are inserted before and after the first ‘1’ in the ‘11’ to obtain: ‘10000000010000111 00 1 00 001 00 000’. At step (4) Q idle slots are then inserted before each ‘1’ after the ‘11’ as follows: ‘1 000 000000001 000 00001 000 1 000 1 00 1 00 001 00 000’. In this exemplary denormalized string, the word tag is identified as: ‘ 00 1 00 1 00 ’.
Slot Sequencing Windowing
It will be appreciated that in exemplary embodiments of the above described encoding methodology the ‘11’ identifier establishes synchronization between the surface and downhole systems. Given the noisy communication channel, there is some likelihood that the ‘11’ identifier may be falsely received at the service or that a transmitted ‘11’ may degrade to a single pulse. In such instances, successively encoded integers may be decoded in error, especially when successive integers are encoded using varying values of n. In exemplary embodiments of the present invention, these types of synchronization losses may be resolved in a cost effective manner using a windowing technique.
In such embodiments a window is defined to include a fixed number of non-negative integers. The window is typically preceded (or followed) by a window tag as described in more detail below. While such a window may include substantially any number of integers, it preferably includes enough integers so that the overhead associated with the window tag does not significantly degrade transmissions efficiency, but not so many integers as to require an excessively long time to resynchronize in the event of a missed or falsely received ‘11’ identifier. Mud pulse telemetry embodiments may advantageously include a window length, for example, in a range from about 10 to about 50 integers. The invention is, of course, not limited in these regards. Nor is the invention limited to the use of a window tag. Such an implementation is purely optional.
In one exemplary embodiment in accordance with the present invention, a window tag may include the normalized string ‘111’. When denormalized, the window tag may advantageously include three pulses distributed in 4Q−1 slots. For example, one advantageous window tag includes Q−1 idle slots before the first pulse, Q−1 idle slots between the first and second pulses, Q−1 idle slots between the second and third pulses, and Q−1 idle slots after the third pulse. Between successive windows, the window tag may be advantageously combined with one of the above described word tags since the slot sequence for a word tag has a common prefix and the same number of idle slots between pulses as long as there are at least Q idle slots before the very first pulse of a number which is to ensure the window tag uniqueness. Such a scheme advantageously reduces overhead. Again, the invention is expressly not limited in these regards.
Surface Detection and Matched Filtering
Proper signal detection is critical to any communication system. Proper signal detection at the surface prior to decoding is especially important in mud pulse telemetry operations, in part due to the extremely noisy communication channel. Signal attenuation and drilling noise (as well as other sources of noise) can cause reception errors and a loss of synchronization between the downhole encoder and the surface decoder. The frequency of these errors may be reduced via surface detection and decoding techniques.
Turning now to FIG. 5 , one exemplary embodiment of a surface detection methodology 150 in accordance with the present invention is depicted in flow chart form. Surface detection, as the name implies, includes detecting (or receiving) the signal (in this case an analog pressure waveform) at the surface ( 152 ). The analog waveform may be received at the surface using substantially any suitable transducer or differential transducer arrangement, e.g., as disclosed in U.S. Pat. Nos. 6,421,298 and 7,489,591. The waveform is typically also preprocessed at 154 . Conventional preprocessing may include, for example, digitizing and filtering the waveform (e.g., using analog to digital conversion and filtering or decimation routines). The surface detection method further includes a first matched filtering step at 156 in which the individual word tags (e.g., the 3Q−1 bits described above) are identified thereby enabling the waveform to be further processed word by word (i.e., integer by integer). This matched filtering step may alternatively be configured to identify individual window tags (e.g., the 4Q−1 bits described above) to enable further processing window by window (i.e., one group of integers). While the invention is described in more detail below in terms of a word by word algorithm, it will be appreciated the invention is not limited in these regards as this processing may be accomplished two, three, or more words (or windows) at a time.
With continued reference to FIG. 5 , the pulses in a given word (or words) may be identified and located preliminarily at 158 , for example, via setting a pulse threshold. At 160 , the word may be further processed using a second matched filtering step as described in more detail below with respect to FIG. 7 . The word (the encoded integer) may then be decoded at 162 , for example as described above. The decoded integer may then be saved and/or plotted as is conventional in the art. Method steps 156 , 158 , and 160 are now described in more detail, beginning with the first matched filter step performed at 156 .
One exemplary embodiment of matched filtering step 156 is depicted in flow chart form on FIG. 6 . This implementation includes a cross correlation methodology that may be represented mathematically, for example, as follows:
R
12
(
t
)
=
∫
-
∞
∞
G
12
(
ω
)
e
j
ω
t
d
ω
Equation
5
where R 12 (t) represents the cross correlation of the two waveforms, G 12 (ω) represents the cross spectrum of the two waveforms w 1 and w 2 and is defined as H 1 (ω)H* 2 (ω), where H 1 (ω) is the Fourier Transform of w 1 and H* 2 (ω) is the complex conjugate of the Fourier Transform of w 2 . In step 156 ( FIG. 5 ), w 1 represents a portion of the decimated waveform including at least one word and w 2 represents a theoretical waveform for the word tag. The exemplary matched filtering routine depicted also includes a bandpass filtering (BPF) operations by which the DC component of the waveform w 1 may be removed.
With continued reference to FIG. 6 , fast Fourier Transform (FFT) coefficients are computed for w 1 , w 2 , and the bandpass filter coefficients (BPF). The bandpass filter FFT coefficients are then multiplied (complex multiplication) with each of the w 1 and w 2 FFT coefficients. The resultant products are then processed via a complex conjugate multiplication operation as depicted and spectral weighted using a kernel such as a Roth processor or a Wiener processor. The real and imaginary parts of the spectral weighting process may be represented mathematically, for example, as follows:
(f r 2 (k)+f i 2 (k))(r r (k)s r (k)+s i (k)r i (k))
(f r 2 (k)+f i 2 (k))(r i (k)s r (k)−s i (k)r r (k)) Equation 6
where s r (k)+s i (k)j represent the FFT coefficients of w 1 , r r (k)+r i (k)j represent the FFT coefficients of w 2 , f r (k)+f i (k)j represent the FFT coefficients of the impulse response of the bandpass filter, and (0≦k≦L−1) with L being the sample length of waveform w 1 . After spectral weighting, an inverse FFT (IFFT) may be applied to inverse transform the spectrally weighted result back into the time domain. The word tag (or tags) or window tag (or tags) may be identified where the cross correlation is a maximum (or greater than a predetermined threshold).
Individual words (identified as described above) may be further processed as depicted at 158 , 160 , and 162 in FIG. 5 . For example, at 158 the other pulses in the word (the encoded integer) are located. This may be accomplished for example, via evaluating the pulse height of the pulses in the word tag located in 156 and applying a corresponding threshold (e.g., half the pulse height) to the waveform. Once the pulses have been identified and located (the output of step 158 ), the word may optionally be decoded at 162 , for example as described above, in order to obtain the encoded and transmitted integer. While such an approach may be serviceable, a degree of uncertainty remains. In particular, due to the attenuation and noise in the communication channel, pulses are sometimes shifted in time. It is not uncommon for one or more pulses to be located, for example, between adjacent slots.
In one exemplary embodiment of the invention, the certainty of the detected word may be improved via applying a second matched filtering (cross-correlation) algorithm at 160 . With reference now to FIG. 7 , confidence values C 0 i , C −1 i , and C +1 i may be computed for each pulse at 182 . C 0 i represent the confidence values for the i'th pulse as located in the slot in which it was detected (having a slot offset of 0). C −1 i and C +1 i represent the confidence values for the i'th pulse offset one slot earlier (−1) or later (+1) in time. The confidence values C 0 i , C −1 i , and C +1 i may be computed, for example, via considering the noise to signal ratio (NSR) and the relative offset of each peak from a slot center position. The greater the NSR and the relative offset, the lower the confidence value. Confidence values may also be obtained via comparing the low pass filtered signal obtained in 154 with the bandpass filtered signal obtained in 156 . A good peak-to-peak match indicates a high confidence value while a poor peak-to-peak match indicates a low confidence value.
Given that each pulse may be theoretically located in one of three slots, there are a total of 3 M combinations for a given word (where M represents the number of pulses in the word). Each of the 3 M combinations represents a unique potential waveform. In order to obtain the most likely waveform, each of these potential waveforms may be cross correlated with the decimated waveform w 1 using the matched filtering technique described above with respect to FIG. 6 . The waveform with the highest amplitude may be taken as correct. While this approach may be suitable for certain applications, those of ordinary skill will readily appreciate that it is not tractable for even a moderate number of pulses M (e.g., there are 2187 potential waveforms for a word having only 7 pulses).
With continued reference to FIG. 7 , a certain number S of least confident pulses may be selected at 184 . The selected pulses have the lowest valued confidence values C 0 i . For example, only pulses having a confidence value less than some predetermined threshold may be selected. Alternatively, a fixed number of pulses (e.g., five) having the lowest valued confidence values may be selected. In practice, S is preferably a small number (e.g., about 5) such that the algorithm may be efficiently implemented on a conventional DSP chip such as a TI TMS320C6701. For each of the S least confident pulses, the more likely offset may also selected based on the values of C −1 i and C +1 i . This results in 2 S unique combinations for S least confidence pulses. A selective matched detection algorithm in accordance with the present invention may be given, for example, in Algorithm V as follows:
Step (1): Seek S pulses having indices {S i |1≦i≦S} which correspond to S least confidence values in {C 0 i |1≦i≦M}.
Step (2): For each pulse in {S i |1≦i≦s}, select the offset ‘−1’ when C −1 Si >C +1 Si or ‘+1’ when C +1 Si ≧C −1 Si . Steps (1) and (2) may be executed at 184 in FIG. 7
Step (3): Generate a 2 S unique waveforms at 186 based on the 2 S combinations of {S i |1≦i≦S} and the M−S pulses (the “most confident pulses”) that have fixed positions.
Step (4): Apply the matched filtering algorithm depicted in FIG. 6 at 187 to each of the waveforms generated in Step (3).
Step (5): Select the wave form having the highest cross-correlation with the reference waveform (the decimated waveform) at 188 .
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alternations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. | A method for receiving an encoded integer includes acquiring a digitized waveform including a first plurality of pulses distributed among a second plurality of time slots, locating each of the pulses in the digitized waveform, computing a confidence value for each of the pulses, selecting a subset of the plurality of pulses, the subset including pulses having low confidence values computed, generating a set of unique waveforms corresponding to various combinations of the subset of pulses selected, computing a cross-correlation between each of the waveforms generated and the digitized waveform acquired, and selecting the waveform having the highest cross-correlation computed. | 4 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/689,899 filed Jun. 13, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates to lightweight thermoset polymer particles, to processes for the manufacture of such particles, and to applications of such particles. It is possible to use a wide range of thermoset polymers as the main constituents of the particles of the invention, and to produce said particles by means of a wide range of fabrication techniques. Without reducing the generality of the invention, in its currently preferred embodiments, the thermoset polymer consists of a terpolymer of styrene, ethyvinylbenzene and divinylbenzene; suspension polymerization is performed to prepare the particles, and post-polymerization heat treatment is performed with the particles placed in an unreactive gaseous environment with nitrogen as the preferred unreactive gas to further advance the curing of the thermoset polymer. When executed in the manner taught by this disclosure, many properties of both the individual particles and packings of the particles can be improved by the practice of the invention. The particles exhibit enhanced stiffness, strength, heat resistance, and resistance to aggressive environments; as well as the improved retention of high conductivity of liquids and gases through packings of the particles in aggressive environments under high compressive loads at elevated temperatures. The thermoset polymer particles of the invention can be used in many applications. These applications include, but are not limited to, the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells; for example, as a proppant partial monolayer, a proppant pack, an integral component of a gravel pack completion, a ball bearing, a solid lubricant, a drilling mud constituent, and/or a cement additive.
BACKGROUND
[0003] The background of the invention can be described most clearly, and hence the invention can be taught most effectively, by subdividing this section in three subsections. The first subsection will provide some general background regarding the role of crosslinked (and especially stiff and strong thermoset) particles in the field of the invention. The second subsection will describe the prior art that has been taught in the patent literature. The third subsection will provide additional relevant background information selected from the vast scientific literature on polymer materials science and chemistry, to further facilitate the teaching of the invention.
[0000] A. General Background
[0004] Crosslinked polymer (and especially stiff and strong thermoset) particles are used in many applications requiring high stiffness, high mechanical strength, high temperature resistance, and/or high resistance to aggressive environments. Crosslinked polymer particles can be prepared by reacting monomers or oligomers possessing three or more reactive chemical functionalities, as well as by reacting mixtures of monomers and/or oligomers at least one ingredient of which possesses three or more reactive chemical functionalities.
[0005] The intrinsic advantages of crosslinked polymer particles over polymer particles lacking a network consisting of covalent chemical bonds in such applications become especially obvious if an acceptable level of performance must be maintained for a prolonged period (such as many years, or in some applications even several decades) under the combined effects of mechanical deformation, heat, and/or severe environmental insults. For example, many high-performance thermoplastic polymers, which have excellent mechanical properties and which are hence used successfully under a variety of conditions, are unsuitable for applications where they must maintain their good mechanical properties for many years in the presence of heat and/or chemicals, because they consist of assemblies of individual polymer chains. Over time, the deformation of such assemblies of individual polymer chains at an elevated temperature can cause unacceptable amounts of creep, and furthermore solvents and/or aggressive chemicals present in the environment can gradually diffuse into them and degrade their performance severely (and in some cases even dissolve them). By contrast, the presence of a well-formed continuous network of covalent bonds restrains the molecules, thus helping retain an acceptable level of performance under severe use conditions over a much longer time period.
[0006] Oil and natural gas well construction activities, including drilling, completion and stimulation applications (such as proppants, gravel pack components, ball bearings, solid lubricants, drilling mud constituents, and/or cement additives), require the use of particulate materials, in most instances preferably of as nearly spherical a shape as possible. These (preferably substantially spherical) particles must generally be made from materials that have excellent mechanical properties. The mechanical properties of greatest interest in most such applications are stiffness (resistance to deformation) and strength under compressive loads, combined with sufficient “toughness” to avoid the brittle fracture of the particles into small pieces commonly known as “fines”. In addition, the particles must have excellent heat resistance in order to be able to withstand the combination of high compressive load and high temperature that normally becomes increasingly more severe as one drills deeper. In other words, particles that are intended for use deeper in a well must be able to withstand not only the higher overburden load resulting from the greater depth, but also the higher temperature that accompanies that higher overburden load as a result of the nature of geothermal gradients. Finally, these materials must be able to withstand the effects of the severe environmental insults (resulting from the presence of a variety of hydrocarbon and possibly solvent molecules as well as water, at simultaneously elevated temperatures and compressive loads) that the particles will encounter deep in an oil or natural gas well. The need for relatively lightweight high performance materials for use in these particulate components in applications related to the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells thus becomes obvious. Consequently, while such uses constitute only a small fraction of the applications of stiff and strong materials, they provide fertile territory for the development of new or improved materials and manufacturing processes for the fabrication of such materials.
[0007] We will focus much of the remaining discussion of the background of the invention on the use of particulate materials as proppants. One key measure of end use performance of proppants is the retention of high conductivity of liquids and gases through packings of the particles in aggressive environments under high compressive loads at elevated temperatures.
[0008] The use of stiff and strong solid proppants has a long history in the oil and natural gas industry. Throughout most of this history, particles made from polymeric materials (including crosslinked polymers) have been considered to be unsuitable for use by themselves as proppants. The reason for this prejudice is the perception that polymers are too deformable, as well as lacking in the ability to withstand the combination of elevated compressive loads, temperatures and aggressive environments that are commonly encountered in oil and natural gas wells. Consequently, work on proppant material development has focused mainly on sands, on ceramics, and on sands and ceramics coated by crosslinked polymers to improve some aspects of their performance. This situation has prevailed despite the fact that most polymers have densities that are much closer to that of water so that in particulate form they can be transported much more readily into a fracture by low-density fracturing or carrier fluids such as unviscosified water.
[0009] Nonetheless, the obvious practical advantages [see a review by Edgeman (2004)] of developing the ability to use lightweight particles that possess almost neutral buoyancy relative to water have stimulated a considerable amount of work over the years. However, as will be seen from the review of the prior art provided below, progress in this field of invention has been very slow as a result of the many technical challenges that exist to the successful development of cost-effective lightweight particles that possess sufficient stiffness, strength and heat resistance.
[0000] B. Prior Art
[0010] The prior art can be described most clearly, and hence the invention can be placed in the proper context most effectively, by subdividing this section into two subsections. The first subsection will describe prior art related to the development of “as-polymerized” thermoset polymer particles. The second subsection will describe prior art related to the development of thermoset polymer particles that are subjected to post-polymerization heat treatment.
[0000] 1. “As-Polymerized” Thermoset Polymer Particles
[0011] As discussed above, particles made from polymeric materials have historically been considered to be unsuitable for use by themselves as proppants. Consequently, their past uses in proppant materials have focused mainly on their placement as coatings on sands and ceramics, in order to improve some aspects of the performance of the sand and ceramic proppants.
[0012] Significant progress was made in the use of crosslinked polymeric particles themselves as constituents of proppant formulations in prior art taught by Rickards, et al. (U.S. Pat. No. 6,059,034; U.S. Pat. No. 6,330,916). However, these inventors still did not consider or describe the polymeric particles as proppants. Their invention only related to the use of the polymer particles in blends with particles of more conventional proppants such as sands or ceramics. They taught that the sand or ceramic particles are the proppant particles, and that the “deformable particulate material” consisting of polymer particles mainly serves to improve the fracture conductivity, reduce the generation of fines and/or reduce proppant flowback relative to the unblended sand or ceramic proppants. Thus while their invention differs significantly from the prior art in the sense that the polymer is used in particulate form rather than being used as a coating, it shares with the prior art the limitation that the polymer still serves merely as a modifier improving the performance of a sand or ceramic proppant rather than being considered for use as a proppant in its own right.
[0013] Bienvenu (U.S. Pat. No. 5,531,274) disclosed progress towards the development of lightweight proppants consisting of high-strength crosslinked polymeric particles for use in hydraulic fracturing applications. However, embodiments of this prior art, based on the use of styrene-divinylbenzene (S-DVB) copolymer beads manufactured by using conventional fabrication technology and purchased from a commercial supplier, failed to provide an acceptable balance of performance and price. They cost far more than the test standard (Jordan sand) while being outperformed by Jordan sand in terms of the liquid conductivity and liquid permeability characteristics of their packings measured according to the industry-standard API RP 61 testing procedure. [This procedure is described by the American Petroleum Institute in its publication titled “Recommended Practices for Evaluating Short Term Proppant Pack Conductivity” (first edition, Oct. 1, 1989).] The need to use a very large amount of an expensive crosslinker (50 to 80% by weight of DVB) in order to obtain reasonable performance (not too inferior to that of Jordan Sand) was a key factor in the higher cost that accompanied the lower performance.
[0014] The most advanced prior art in stiff and strong crosslinked “as-polymerized” polymer particle technologies for use in applications in oil and natural gas drilling was developed by Albright (U.S. Pat. No. 6,248,838) who taught the concept of a “rigid chain entanglement crosslinked polymer”. In summary, the reactive formulation and the processing conditions were modified to achieve “rapid rate polymerization”. While not improving the extent of covalent crosslinking relative to conventional isothermal polymerization, rapid rate polymerization results in the “trapping” of an unusually large number of physical entanglements in the polymer. These additional entanglements can result in a major improvement of many properties. For example, the liquid conductivities of packings of S-DVB copolymer beads with w DVB =0.2 synthesized via rapid rate polymerization are comparable to those that were found by Bienvenu (U.S. Pat. No. 5,531,274) for packings of conventionally produced S-DVB beads at the much higher DVB level of w DVB =0.5. Albright (U.S. Pat. No. 6,248,838) thus provided the key technical breakthrough that enabled the development of the first generation of crosslinked polymer beads possessing sufficiently attractive combinations of performance and price characteristics to result in their commercial use in their own right as solid polymeric proppants.
[0000] 2. Heat-Treated Thermoset Polymer Particles
[0015] There is no prior art that relates to the development of heat-treated thermoset polymer particles that have not been reinforced by rigid fillers or by nanofillers for use in oil and natural gas well construction applications. One needs to look into another field of technology to find prior art of some relevance related to such “unfilled” heat-treated thermoset polymer particles. Nishimori, et. al. (JP1992-22230) focused on the development of particles for use in liquid crystal display panels. They taught the use of post-polymerization heat treatment to increase the compressive elastic modulus of S-DVB particles at room temperature. They only claimed compositions polymerized from reactive monomer mixtures containing 20% or more by weight of DVB or other crosslinkable monomer(s) prior to the heat treatment. They stated explicitly that improvements obtained with lower weight fractions of the crosslinkable monomer(s) were insufficient and that hence such compositions were excluded from the scope of their patent.
[0000] C. Scientific Literature
[0016] The development of thermoset polymers requires the consideration of a vast and multidisciplinary range of polymer materials science and chemistry challenges. It is essential to convey these challenges in the context of the fundamental scientific literature.
[0017] Bicerano (2002) provides a broad overview of polymer materials science that can be used as a general reference for most aspects of the following discussion. Additional references will also be provided below, to other publications which treat specific issues in greater detail than what could be accommodated in Bicerano (2002).
[0018] 1. Selected Fundamental Aspects of the Curing of Crosslinked Polymers
[0019] It is essential, first, to review some fundamental aspects of the curing of crosslinked polymers, which are applicable to such polymers regardless of their form (particulate, coating, or bulk).
[0020] The properties of crosslinked polymers prepared by standard manufacturing processes are often limited by the fact that such processes typically result in incomplete curing. For example, in an isothermal polymerization process, as the glass transition temperature (T g ) of the growing polymer network increases, it may reach the polymerization temperature while the reaction is still in progress. If this happens, then the molecular motions slow down significantly so that further curing also slows down significantly. Incomplete curing yields a polymer network that is less densely crosslinked than the theoretical limit expected from the functionalities and relative amounts of the starting reactants. For example, a mixture of monomers might contain 80% DVB by weight as a crosslinker but the final extent of crosslinking that is attained may not be much greater than what was attained with a much smaller percentage of DVB. This situation results in lower stiffness, lower strength, lower heat resistance, and lower environmental resistance than the thermoset is capable of manifesting when it is fully cured and thus maximally crosslinked.
[0021] When the results of the first scan and the second scan of S-DVB beads containing various weight fractions of DVB (w DVB ), obtained by Differential Scanning Calorimetry (DSC), as reported by Bicerano, et al. (1996) (see FIG. 1 ) are compared, it becomes clear that the low performance and high cost of the “as purchased” S-DVB beads utilized by Bienvenu (U.S. Pat. No. 5,531,274) are related to incomplete curing. This incomplete curing results in the ineffective utilization of DVB as a crosslinker and thus in the incomplete development of the crosslinked network. In summary, Bicerano, et al. (1996), showed that the T g of typical “as-polymerized” S-DVB copolymers, as measured by the first DSC scan, increased only slowly with increasing w DVB , and furthermore that the rate of further increase of T g slowed down drastically for w DVB >0.08. By contrast, in the second DSC scan (performed on S-DVB specimens whose curing had been driven much closer to completion as a result of the temperature ramp that had been applied during the first scan), T g grew much more rapidly with w DVB over the entire range of up to w DVB =0.2458 that was studied. The more extensively cured samples resulting from the thermal history imposed by the first DSC scan can, thus, be considered to provide much closer approximations to the ideal theoretical limit of a “fully cured” polymer network.
[0022] 2. Effects of Heat Treatment on Key Properties of Thermoset Polymers
[0023] a. Maximum Possible Use Temperature
[0024] As was illustrated by Bicerano, et al. (1996) for S-DVB copolymers with w DVB of up to 0.2458, enhancing the state of cure of a thermoset polymer network can increase T g very significantly relative to the T g of the “as-polymerized” material. In practice, the heat distortion temperature (HDT) is used most often as a practical indicator of the softening temperature of a polymer under load. As was shown by Takemori (1979), a systematic understanding of the HDT is possible through its direct correlation with the temperature dependences of the tensile (or equivalently, compressive) and shear elastic moduli. For amorphous polymers, the precipitous decrease of these elastic moduli as T g is approached from below renders the HDT well-defined, reproducible, and predictable. HDT is thus closely related to (and usually slightly lower than) T g for amorphous polymers, so that it can be increased significantly by increasing T g significantly.
[0025] The HDT decreases gradually with increasing magnitude of the load used in its measurement. For example, for general-purpose polystyrene (which has T g =100° C.), HDT=95° C. under a load of 0.46 MPa and HDT=85° C. under a load of 1.82 MPa are typical values. However, the compressive loads deep in an oil well or natural gas well are normally far higher than the standard loads (0.46 MPa and 1.82 MPa) used in measuring the HDT. Consequently, amorphous thermoset polymer particles can be expected to begin to deform significantly at a lower temperature than the HDT of the polymer measured under the standard high load of 1.82 MPa. This deformation will cause a decrease in the conductivities of liquids and gases through the propped fracture, and hence in the loss of effectiveness as a proppant, at a somewhat lower temperature than the HDT value of the polymer measured under the standard load of 1.82 MPa.
[0026] b. Mechanical Properties
[0027] As was discussed earlier, Nishimori, et. al. (JP1992-22230) used heat treatment to increase the compressive elastic modulus of their S-DVB particles (intended for use in liquid crystal display panels) significantly at room temperature (and hence far below T g ). Deformability under a compressive load is inversely proportional to the compressive elastic modulus. It is, therefore, important to consider whether one may also anticipate major benefits from heat treatment in terms of the reduction of the deformability of thermoset polymer particles intended for oil and natural gas drilling applications, when these particles are used in subterranean environments where the temperature is far below the T g of the particles. As explained below, the enhancement of curing via post-polymerization heat treatment is generally expected to have a smaller effect on the compressive elastic modulus (and hence on the proppant performance) of thermoset polymer particles when used in oil and natural gas drilling applications at temperatures far below their T g .
[0028] Nishimori, et. al. (JP1992-22230) used very large amounts of DVB (w DVB >>0.2). By contrast, in general, much smaller amounts of DVB (w DVB ≦0.2) must be used for economic reasons in the “lower value” oil and natural gas drilling applications. The elastic moduli of a polymer at temperatures far below T g are determined primarily by deformations that are of a rather local nature and hence on a short length scale. Some enhancement of the crosslink density via further curing (when the network junctions created by the crosslinks are far away from each other to begin with) will hence not normally have nearly as large an effect on the elastic moduli as when the network junctions are very close to each other to begin with and then are brought even closer by the enhancement of curing via heat treatment. Consequently, while the compressive elastic modulus can be expected to increase significantly upon heat treatment when w DVB is very large, any such effect will normally be less pronounced at low values of w DVB . In summary, it can thus generally be expected that the enhancement of the compressive elastic modulus at temperatures far below T g will probably be small for the types of formulations that are most likely to be used in the synthesis of thermoset polymer particles for oil and natural gas drilling applications.
SUMMARY OF THE INVENTION
[0029] The present invention involves a novel approach towards the practical development of stiff, strong, tough, heat resistant, and environmentally resistant ultralightweight particles, for use in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells.
[0030] The disclosure is summarized below in three key aspects: (A) Compositions of Matter (thermoset particles that exhibit improved properties compared with prior art), (B) Processes (methods for manufacture of the compositions of matter), and (C) Applications (utilization of the compositions of matter in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells).
[0031] The disclosure describes lightweight thermoset polymer particles whose properties are improved relative to prior art. The particles targeted for development include, but are not limited to, terpolymers of styrene, ethyvinylbenzene and divinylbenzene. The particles exhibit any one or any combination of the following properties: enhanced stiffness, strength, heat resistance, and/or resistance to aggressive environments; and/or improved retention of high conductivity of liquids and/or gases through packings of the particles when the packings are placed in potentially aggressive environments under high compressive loads at elevated temperatures.
[0032] The disclosure also describes processes that can be used to manufacture the particles. The fabrication processes targeted for development include, but are not limited to, suspension polymerization to prepare the “as-polymerized” particles, and post-polymerization process(es) to further advance the curing of the polymer. The post-polymerization process(es) may optionally comprise heat treatment. The particles during the heat treatment are placed in an unreactive gaseous environment with nitrogen as the preferred unreactive gas.
[0033] The disclosure finally describes the use of the particles in practical applications. The targeted applications include, but are not limited to, the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells; for example, as a proppant partial monolayer, a proppant pack, an integral component of a gravel pack completion, a ball bearing, a solid lubricant, a drilling mud constituent, and/or a cement additive.
[0000] A. Compositions of Matter
[0034] The compositions of matter of the present invention are thermoset polymer particles. Any additional formulation component(s) familiar to those skilled in the art can also be used during the preparation of the particles; such as initiators, catalysts, inhibitors, dispersants, stabilizers, rheology modifiers, buffers, antioxidants, defoamers, impact modifiers, plasticizers, pigments, flame retardants, smoke retardants, or mixtures thereof. Some of the the additional component(s) may also become either partially or completely incorporated into the particles in some embodiments of the invention. However, the only required component of the particles is a thermoset polymer.
[0035] Any rigid thermoset polymer may be used as the polymer of the present invention. Rigid thermoset polymers are, in general, amorphous polymers where covalent crosslinks provide a three-dimensional network. However, unlike thermoset elastomers (often referred to as “rubbers”) which also possess a three-dimensional network of covalent crosslinks, the rigid thermosets are, by definition, “stiff”. In other words, they have high elastic moduli at “room temperature” (25° C.), and often up to much higher temperatures, because their combinations of chain segment stiffness and crosslink density result in a high glass transition temperature.
[0036] Some examples of rigid thermoset polymers that can be used as materials of the invention will be provided below. It is to be understood that these examples are being provided without reducing the generality of the invention, merely to facilitate the teaching of the invention.
[0037] Commonly used rigid thermoset polymers include, but are not limited to, crosslinked epoxies, epoxy vinyl esters, polyesters, phenolics, melamine-based resins, polyurethanes, and polyureas. Rigid thermoset polymers that are used less often because of their high cost despite their exceptional performance include, but are not limited to, crosslinked polyimides. These various types of polymers can, in different embodiments of the invention, be prepared by starting either from their monomers, or from oligomers that are often referred to as “prepolymers”, or from suitable mixtures of monomers and oligomers.
[0038] Many additional types of rigid thermoset polymers can also be used in particles of the invention, and are all within the scope of the invention. Such polymers include, but are not limited to, various families of crosslinked copolymers prepared most often by the polymerization of vinylic monomers, of vinylidene monomers, or of mixtures thereof.
[0039] The “vinyl fragment” is commonly defined as the CH 2 ═CH— fragment. So a “vinylic monomer” is a monomer of the general structure CH 2 ═CHR where R can be any one of a vast variety of molecular fragments or atoms (other than hydrogen). When a vinylic monomer CH 2 ═CHR reacts, it is incorporated into the polymer as the —CH 2 —CHR— repeat unit. Among rigid thermosets built from vinylic monomers, the crosslinked styrenics and crosslinked acrylics are especially familiar to workers in the field. Some other familiar types of vinylic monomers (among others) include the olefins, vinyl alcohols, vinyl esters, and vinyl halides.
[0040] The “vinylidene fragment” is commonly defined as the CH 2 ═CR″— fragment. So a “vinylidene monomer” is a monomer of the general structure CH 2 ═CR′R″ where R′ and R″ can each be any one of a vast variety of molecular fragments or atoms (other than hydrogen). When a vinylidene monomer CH 2 ═CR′R″ reacts, it is incorporated into a polymer as the —CH 2 —CR′R″-repeat unit. Among rigid thermosets built from vinylidene polymers, the crosslinked alkyl acrylics [such as crosslinked poly(methyl methacrylate)] are especially familiar to workers in the field. However, vinylidene monomers similar to each type of vinyl monomer (such as the styrenics, acrylates, olefins, vinyl alcohols, vinyl esters and vinyl halides, among others) can be prepared. One example of particular interest in the context of styrenic monomers is □-methyl styrene, a vinylidene-type monomer that differs from styrene (a vinyl-type monomer) by having a methyl (—CH 3 ) group serving as the R″ fragment replacing the hydrogen atom attached to the □-carbon.
[0041] Thermosets based on vinylic monomers, on vinylidene monomers, or on mixtures thereof, are typically prepared by the reaction of a mixture containing one or more non-crosslinking (difunctional) monomer and one or more crosslinking (three or higher functional) monomers. All variations in the choices of the non-crosslinking monomer(s), the crosslinking monomers(s), and their relative amounts [subject solely to the limitation that the quantity of the crosslinking monomer(s) must not be less than 1% by weight], are within the scope of the invention.
[0042] Without reducing the generality of the invention, in its currently preferred embodiments, the thermoset polymer particles consist of a terpolymer of styrene (non-crosslinking), ethyvinylbenzene (also non-crosslinking), and divinylbenzene (crosslinking), with the weight fraction of divinylbenzene ranging from 3% to 35% by weight of the starting monomer mixture.
[0000] B. Processes
[0043] If a suitable post-polymerization process step is applied to thermoset polymer particles, in many cases the curing reaction will be driven further towards completion so that T g (and hence also the maximum possible use temperature) will increase. This is the most commonly obtained benefit of applying a post-polymerization process step. In some instances, there may also be further benefits, such as an increase in the compressive elastic modulus even at temperatures that are far below T g , and an increase of such magnitude in the resistance to aggressive environments as to enhance significantly the potential range of applications of the particles.
[0044] Processes that may be used to enhance the degree of curing of a thermoset polymer include, but are not limited to, heat treatment (which may be combined with stirring, flow and/or sonication to enhance its effectiveness), electron beam irradiation, and ultraviolet irradiation. FIG. 2 provides an idealized schematic illustration of the benefits of implementing such methods. We focused mainly on the use of heat treatment in order to increase the T g of the thermoset polymer.
[0045] The processes that may be used for the fabrication of the thermoset polymer particles of the invention comprise two major steps. The first step is the formation of the particles by means of a polymerization process. The second step is the use of an appropriate postcuring method to advance the curing reaction and to thus obtain a thermoset polymer network that approaches the “fully cured” limit. Consequently, this subsection will be further subdivided into two subsections, dealing with polymerization and with postcure respectively.
[0046] 1. Polymerization and Network Formation
[0047] Any method for the fabrication of thermoset polymer particles known to those skilled in the art may be used to prepare embodiments of the particles of the invention. Without reducing the generality of the invention, our preferred method will be discussed below to facilitate the teaching of the invention.
[0048] It is especially practical to prepare the particles by using methods that can produce the particles directly in the desired (usually substantially spherical) shape during polymerization from the starting monomers. (While it is a goal of this invention to create spherical particles, it is understood that it is exceedingly difficult as well as unnecessary to obtain perfectly spherical particles. Therefore, particles with minor deviations from a perfectly spherical shape are considered perfectly spherical for the purposes of this disclosure.) Suspension (droplet) polymerization is the most powerful method available for accomplishing this objective.
[0049] Two main approaches exist to suspension polymerization. The first approach is isothermal polymerization which is the conventional approach that has been practiced for many decades. The second approach is “rapid rate polymerization” as taught by Albright (U.S. Pat. No. 6,248,838) which is incorporated herein by reference in its entirety. Without reducing the generality of the invention, suspension polymerization as performed via the rapid rate polymerization approach taught by Albright (U.S. Pat. No. 6,248,838) is used in the current preferred embodiments of the invention.
[0050] 2. Post-Polymerization Advancement of Curing and Network Formation
[0051] As was discussed earlier and illustrated in FIG. 1 with the data of Bicerano, et al. (1996), typical processes for the synthesis of thermoset polymers may result in the formation of incompletely cured networks, and may hence produce thermosets with lower glass transition temperatures and lower maximum use temperatures than is achievable with the chosen formulation of reactants. Consequently, the use of a post-polymerization process step (or a sequence of such process steps) to advance the curing of a thermoset polymer particle of the invention is an aspect of the invention. Suitable methods include, but are not limited to, heat treatment (also known as “annealing”), electron beam irradiation, and ultraviolet irradiation.
[0052] Post-polymerization heat treatment is a very powerful method for improving the properties and performance of S-DVB copolymers (as well as of many other types of thermoset polymers) by helping the polymer network approach its “full cure” limit. It is, in fact, the most easily implementable method for advancing the state of cure of S-DVB copolymer particles. However, it is important to recognize that another post-polymerization method (such as electron beam irradiation or ultraviolet irradiation) may be the most readily implementable one for advancing the state of cure of some other type of thermoset polymer. The use of any suitable method for advancing the curing of the thermoset polymer that is being used as a particle of the present invention after polymerization is within the scope of the invention.
[0053] Without reducing the generality of the invention, among the suitable methods, heat treatment is used as the post-polymerization method to enhance the curing of the thermoset polymer in the preferred embodiments of the invention. Any desired thermal history can be imposed; such as, but not limited to, isothermal annealing at a fixed temperature; nonisothermal heat exposure with either a continuous or a step function temperature ramp; or any combination of continuous temperature ramps, step function temperature ramps, and/or periods of isothermal annealing at fixed temperatures. In practice, while there is great flexibility in the choice of a thermal history, it must be selected carefully to drive the curing reaction to the maximum final extent possible without inducing unacceptable levels of thermal degradation.
[0054] Any significant increase in T g by means of improved curing will translate directly into an increase of comparable magnitude in the practical softening temperature of the polymer particles under the compressive load imposed by the subterranean environment. Consequently, a significant increase of the maximum possible use temperature of the thermoset polymer particles is the most common benefit of advancing the extent of curing by heat treatment.
[0055] A practical concern during the imposition of heat treatment is related to the amount of material that is being subjected to heat treatment simultaneously. For example, very small amounts of material can be heat treated uniformly and effectively in vacuum; or in any inert (non-oxidizing) gaseous medium, such as, but not limited to, a helium or nitrogen “blanket”. However, heat transfer in a gaseous medium is generally not nearly as effective as heat transfer in an appropriately selected liquid medium. Consequently, during the heat treatment of large quantities of the particles of the invention (such as, but not limited to, the output of a run of a commercial-scale batch production reactor), it is usually necessary to use a liquid medium, and furthermore also to stir the particles vigorously to ensure that the heat treatment is applied as uniformly as possible. Serious quality problems may arise if heat treatment is not applied uniformly; for example, as a result of the particles that were initially near the heat source being overexposed to heat and thus damaged, while the particles that were initially far away from the heat source are not exposed to sufficient heat and are thus not sufficiently postcured.
[0056] If a gaseous or a liquid heat treatment medium is used, the medium may contain, without limitation, one or a mixture of any number of types of constituents of different molecular structure. However, in practice, the medium must be selected carefully to ensure that its molecules will not react with the crosslinked polymer particles to a sufficient extent to cause significant oxidative and/or other types of chemical degradation. In this context, it must also be kept in mind that many types of molecules which do not react with a polymer at ambient temperature may react strongly with the polymer at elevated temperatures. The most relevant example in the present context is that oxygen itself does not react with S-DVB copolymers at room temperature, while it causes severe oxidative degradation of S-DVB copolymers at elevated temperatures where there would not be much thermal degradation in its absence.
[0057] Furthermore, in considering the choice of medium for heat treatment, it is also important to keep in mind that the molecules constituting a molecular fluid can swell organic polymers, potentially causing “plasticization” and thus resulting in undesirable reductions of T g and of the maximum possible use temperature. The magnitude of any such detrimental effect increases with increasing similarity between the chemical structures of the molecules in the heat treatment medium and of the polymer chains. For example, a heat transfer fluid consisting of aromatic molecules will tend to swell a styrene-divinylbenzene copolymer particle. The magnitude of this detrimental effect will increase with decreasing relative amount of the crosslinking monomer (divinylbenzene) used in the formulation. For example, a styrene-divinylbenzene copolymer prepared from a formulation containing only 3% by weight of divinylbenzene will be far more susceptible to swelling in an aromatic liquid than a copolymer prepared from a formulation containing 35% divinylbenzene.
[0058] Geothermal gradients determine the temperature of the downhole environment. The temperature can be sufficiently high in some downhole environments to become effective in the postcuring of some compositions of matter covered by the invention. Consequently, the “in situ” postcuring of the polymer particles, wherein the particles are placed in the downhole environment of a hydrocarbon reservoir without heat treatment and the heat treatment then takes place in the environment as a result of the elevated temperature of the environment, is also within the scope of the invention.
[0059] It is important to note that the polymer particles are kept in the downhole environment of a hydrocarbon reservoir for a very long time in many applications. Consequently, temperatures which may be too low to provide a reasonable cycle time in postcuring as a manufacturing step may often be adequate for the “in situ” postcuring of the particles in the downhole environment during use. On the other hand, the implementation of postcuring as a manufacturing step often has the advantage of providing for better quality control and greater uniformity of particle properties. While each of these two approaches may hence be more suitable than the other one for use in different situations, they both fall within the scope of the invention. Furthermore, their combination by (a) applying a postcuring step during manufacture to advance polymerization and network formation, followed by (b) the “in situ” completion of the postcuring in the downhole environment, is also within the scope of the invention.
[0060] Various means known to those skilled in the art, including but not limited to the stirring, flow and/or sonication of an assembly of particles being subjected to heat treatment, may also be optionally used to enhance further the effectiveness of the heat treatment. The rate of thermal equilibration under a given thermal gradient, possibly combined with the application of any such additional means, depends on many factors. These factors include, but are not limited to, the amount of polymer particles being heat treated simultaneously, the shapes and certain key physical and transport properties of these particles, the shape of the vessel being used for heat treatment, the medium being used for heat treatment, whether external disturbances (such as stirring, flow and/or sonication) are being used to accelerate equilibration, and the details of the heat exposure schedule. Simulations based on the solution of the heat transfer equations may hence be used optionally to optimize the heat treatment equipment and/or the heat exposure schedule.
[0061] Without reducing the generality of the invention, in its currently preferred embodiments, the thermoset polymer particles are placed in an unreactive gaseous environment with nitrogen as the preferred unreactive gas during heat treatment. Appropriately chosen equipment is used, along with simulations based on the solution of the heat transfer equations, to optimize the heat exposure schedule so that large batches of particles can undergo thermal exposure to an extent that is sufficient to accomplish the desired effects of the heat treatment without many particles undergoing detrimental overexposure. This embodiment of the heat treatment process works especially well (without adverse effects such as degradation that could occur if an oxidative gaseous environment such as air were used and/or swelling that could occur if a liquid environment were used) in enhancing the curing of the thermoset polymer. It is, however, important to reemphasize the much broader scope of the invention and the fact that the particular currently preferred embodiments summarized above constitute just a few among the vast variety of possible qualitatively different classes of embodiments.
[0000] C. Applications
[0062] The obvious practical advantages [see a review by Edgeman (2004)] of developing the ability to use lightweight particles that possess almost neutral buoyancy relative to water have stimulated a considerable amount of work over the years. However, progress in this field of invention has been very slow as a result of the many technical challenges that exist to the successful development of cost-effective lightweight particles that possess sufficient stiffness, strength and heat resistance. The present invention has resulted in the development of such stiff, strong, tough, heat resistant, and environmentally resistant ultralightweight particles; and also of cost-effective processes for the fabrication of the particles. As a result, a broad range of potential applications can be envisioned and are being pursued for the use of the thermoset polymer particles of the invention in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells. Without reducing the generality of the invention, in its currently preferred embodiments, the specific applications that are already being evaluated are as a proppant partial monolayer, a proppant pack, an integral component of a gravel pack completion, a ball bearing, a solid lubricant, a drilling mud constituent, and/or a cement additive.
[0063] The use of assemblies of the particles as proppant partial monolayers and/or as proppant packs generally requires the particles to possess significant stiffness and strength under compressive deformation, heat resistance, and resistance to aggressive environments. Enhancements in these properties result in the ability to use the particles as proppants in hydrocarbon reservoirs that exert higher compressive loads and/or possess higher temperatures.
[0064] The most commonly used measure of proppant performance is the conductivity of liquids and/or gases (depending on the type of hydrocarbon reservoir) through packings of the particles. A minimum liquid conductivity of 100 mDft is often considered as a practical threshold for considering a packing to be useful in propping a fracture that possesses a given closure stress at a given temperature. It is also a common practice in the industry to use the simulated environment of a hydrocarbon reservoir in evaluating the conductivities of packings of particles. The API RP 61 method is currently the commonly accepted testing standard for conductivity testing in the simulated environment of a hydrocarbon reservoir. As of the date of this filing, however, work is underway to develop alternative testing standards.
[0065] It is also important to note that the current selection of preferred embodiments of the invention has resulted from our focus on application opportunities in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells. Many other applications can also be envisioned for the compositions of matter that fall within the scope of thermoset polymer particles of the invention, extending far beyond their uses by the oil and natural gas industry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0066] The accompanying drawings, which are included to provide further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0067] FIG. 1 shows the effects of advancing the curing reaction in a series of isothermally polymerized styrene-divinylbenzene (S-DVB) copolymers containing different DVB weight fractions via heat treatment. The results of scans of S-DVB beads containing various weight fractions of DVB (w DVB ), obtained by Differential Scanning Calorimetry (DSC), and reported by Bicerano, et al. (1996), are compared. It is seen that the T g of typical “as-polymerized” S-DVB copolymers, as measured by the first DSC scan, increased only slowly with increasing w DVB , and furthermore that the rate of further increase of T g slowed down drastically for w DVB >0.08. By contrast, in the second DSC scan (performed on S-DVB specimens whose curing had been driven much closer to completion as a result of the temperature ramp that had been applied during the first scan), T g grew much more rapidly with w DVB over the entire range of up to w DVB =0.2458 that was studied.
[0068] FIG. 2 provides an idealized schematic illustration, in the context of the resistance of thermoset polymer particles to compression as a function of the temperature, of the most common benefits of using the methods of the present invention. In most cases, the densification of the crosslinked polymer network via post-polymerization heat treatment will have the main benefit of increasing the softening (and hence also the maximum possible use) temperature, along with improving the environmental resistance. In some instances, enhanced stiffness and strength at temperatures that are significantly below the softening temperature may be additional benefits.
[0069] FIG. 3 provides a process flow diagram depicting the preparation of the example. It contains four major blocks; depicting the preparation of the aqueous phase (Block A), the preparation of the organic phase (Block B), the mixing of these two phases followed by suspension polymerization (Block C), and the further process steps used after polymerization to obtain the “as-polymerized” and “heat-treated” samples of particles (Block D).
[0070] FIG. 4 shows the variation of the temperature with time during polymerization.
[0071] FIG. 5 shows the results of differential scanning calorimetry (DSC) scans. Sample AP manifests a large exothermic curing peak region instead of a glass transition region when it is heated. Sample AP is, hence, partially (and in fact only quite poorly) cured. On the other hand, while the DSC curve of Sample IA20mG170C is too featureless for the software to extract a precise glass transition temperature from it, there is no sign of an exothermic peak. Sample IA20mG170C is, hence, very well-cured. The DSC curves of Sample AP/406h6000psi and Sample IA20mG170C/406h6000psi, which were obtained by exposing Sample AP and Sample IA20mG170C, respectively, to 406 hours of heat at a temperature of 250° F. under a compressive stress of 6000 psi during the liquid conductivity experiments, are also shown. Note that the exothermic peak is missing in the DSC curve of Sample AP/406h6000psi, demonstrating that “in situ” postcuring via heat treatment under conditions simulating a downhole environment has been achieved.
[0072] FIG. 6 provides a schematic illustration of the configuration of the conductivity cell.
[0073] FIG. 7 compares the measured liquid conductivities of packings of particles of 14/16 U.S. mesh size (diameters ranging from 1.19 mm to 1.41 mm) from Sample IA20mG 170C and Sample AP, at a coverage of 0.02 lb/ft 2 , under a closure stress of 5000 psi at a temperature of 220° F., and under a closure stress of 6000 psi at a temperature of 250° F., as functions of the time.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0074] Because the invention will be understood better after further discussion of its currently preferred embodiments, further discussion of the embodiments will now be provided. It is understood that the discussion is being provided without reducing the generality of the invention, since persons skilled in the art can readily imagine many additional embodiments that fall within the full scope of the invention as taught in the SUMMARY OF THE INVENTION section.
[0000] A. Nature, Attributes and Applications of Currently Preferred Embodiments
[0075] The currently preferred embodiments of the invention are lightweight thermoset polymer particles possessing high stiffness, strength, temperature resistance, and resistance to aggressive environments. These attributes, occurring in combination, make the particles especially suitable for use in many challenging applications in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells. The applications include the use of the particles as a proppant partial monolayer, a proppant pack, an integral component of a gravel pack completion, a ball bearing, a solid lubricant, a drilling mud constituent, and/or a cement additive.
[0076] In one embodiment, the polymeric particle has a substantially cured polymer network; wherein a packing of the particles manifests a static conductivity of at least 100 mDft after 200 hours at temperatures greater than 80° F. The particles are made by a method including the steps of: forming a polymer by polymerizing a reactive mixture containing at least one of a monomer, an oligomer, or combinations thereof. The at least one of a monomer, an oligomer, or combinations thereof have three or more reactive functionalities capable of creating crosslinks between polymer chains. The particle is subjected to at least one post-polymerizing process that advances the curing of a polymer network.
[0000] B. Compositions of Matter
[0077] The preferred embodiments of the particles of the invention consist of terpolymers of styrene (S, non-crosslinking), ethyvinylbenzene (EVB, also non-crosslinking), and divinylbenzene (DVB, crosslinking).
[0078] The preference for such terpolymers instead of copolymers of S and DVB is a result of economic considerations. To summarize, DVB comes mixed with EVB in the standard product grades of DVB, and the cost of DVB increases rapidly with increasing purity in special grades of DVB. EVB is a non-crosslinking (difunctional) styrenic monomer. Its incorporation into the thermoset polymer does not result in any significant changes in the properties of the polymer, compared with the use of S as the sole non-crosslinking monomer. Consequently, it is far more cost-effective to use a standard (rather than purified) grade of DVB, thus resulting in a terpolymer where some of the repeat units originate from EVB.
[0079] The amount of DVB in the terpolymer ranges from 3% to 35% by weight of the starting mixture of the three reactive monomers (S, EVB and DVB) because different applications require different maximum possible use temperatures. Even when purchased in standard product grades where it is mixed with a large weight fraction of EVB, DVB is more expensive than S. It is, hence, useful to develop different product grades where the maximum possible use temperature increases with increasing weight fraction of DVB. Customers can then purchase the grades of the particles that meet their specific application needs as cost-effectively as possible.
[0000] C. Polymerization
[0080] Suspension polymerization is performed via rapid rate polymerization, as taught by Albright (U.S. Pat. No. 6,248,838) which is incorporated herein by reference in its entirety, for the fabrication of the particles. Rapid rate polymerization has the advantage, relative to conventional isothermal polymerization, of producing more physical entanglements in thermoset polymers (in addition to the covalent crosslinks).
[0081] The most important additional formulation component (besides the reactive monomers) that is used during polymerization is the initiator. The initiator may consist of one type molecule or a mixture of two or more types of molecules that have the ability to function as initiators. Additional formulation components, such as catalysts, inhibitors, dispersants, stabilizers, rheology modifiers, buffers, antioxidants, defoamers, impact modifiers, plasticizers, pigments, flame retardants, smoke retardants, or mixtures thereof, may also be used when needed. Some of the additional formulation component(s) may become either partially or completely incorporated into the particles in some embodiments of the invention.
[0000] D. Attainable Particle Sizes
[0082] Suspension polymerization produces substantially spherical polymer particles. (While it is a goal of this invention to create spherical particles, it is understood that it is exceedingly difficult as well as unnecessary to obtain perfectly spherical particles. Therefore, particles with minor deviations from a perfectly spherical shape are considered perfectly spherical for the purposes of this disclosure.) The particles can be varied in size by means of a number of mechanical and/or chemical methods that are well-known and well-practiced in the art of suspension polymerization. Particle diameters attainable by such means range from submicron values up to several millimeters. Hence the particles may be selectively manufactured over the entire range of sizes that are of present interest and/or that may be of future interest for applications in the oil and natural gas industry.
[0000] E. Optional Further Selection of Particles by Size
[0083] Optionally, after the completion of suspension polymerization, the particles can be separated into fractions having narrower diameter ranges by means of methods (such as, but not limited to, sieving techniques) that are well-known and well-practiced in the art of particle separations. The narrower diameter ranges include, but are not limited to, nearly monodisperse distributions. Optionally, assemblies of particles possessing bimodal or other types of special distributions, as well as assemblies of particles whose diameter distributions follow statistical distributions such as gaussian or log-normal, can also be prepared.
[0084] The optional preparation of assemblies of particles having diameter distributions of interest from any given “as polymerized” assembly of particles can be performed before or after the heat treatment of the particles. Without reducing the generality of the invention, in the currently most preferred embodiments of the invention, any optional preparation of assemblies of particles having diameter distributions of interest from the product of a run of the pilot plant or production plant reactor is performed after the completion of the heat treatment of the particles.
[0085] The particle diameters of current practical interest for various uses in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells range from 0.1 to 4 millimeters. The specific diameter distribution that would be most effective under given circumstances depends on the details of the subterranean environment in addition to depending on the type of application. The diameter distribution that would be most effective under given circumstances may be narrow or broad, monomodal or bimodal, and may also have other special features (such as following a certain statistical distribution function) depending on both the details of the subterranean environment and the type of application.
[0000] F. Heat Treatment
[0086] The particles are placed in an unreactive gaseous environment with nitrogen as the preferred unreactive gas during heat treatment in the currently preferred embodiment of the invention. The inreactive gas thus serves as the heat treatment medium. This approach works especially well (without adverse effects such as degradation that could occur if an oxidative gaseous environment such as air were used and/or swelling that could occur if a liquid environment were used) in enhancing the curing of the particles.
[0087] Gases are much less effective than liquids as heat transfer media. The use of a gaseous rather than a liquid environment hence presents engineering challenges to the heat treatment of very large batches of particles. However, these challenges to practical implementation are overcome by means of the proper choice of equipment and by the use of simulation methods.
[0088] Detailed and realistic simulations based on the solution of the heat transfer equations are hence often used optionally to optimize the heat exposure schedule. It has been found that such simulations become increasingly useful with increasing quantity of particles that will be heat treated simultaneously. The reason is the finite rate of heat transfer. The finite rate results in slower and more difficult equilibration with increasing quantity of particles and hence makes it especially important to be able to predict how to cure most of the particles further uniformly and sufficiently without overexposing many of the particles to heat.
[0089] In performing heat treatment as a manufacturing step as described above, which is the preferred embodiment of the invention, the useful temperature range is from 120° C. to 250° C., inclusive. The duration of the exposure will, in practice, decrease with the maximum temperature of exposure. More specifically, if the heat treatment temperature is 120° C., at least four hours of exposure to that temperature will be required. On the other hand, if the heat treatment temperature is 250° C., the duration of exposure to that temperature will not exceed 20 minutes. In the most preferred embodiments of the invention, the particles undergo a total exposure to temperatures in the range of 150° C. to 200° C. for a duration of 10 minutes to 90 minutes, inclusive.
[0090] In other embodiments of the invention, where heat treatment is performed “in situ” in the downhole environment, the minimum downhole temperature is 80° C. and the minimum dwell time in the downhole environment is one week. In practice, the minimum required amount of time for adequate postcuring in the downhole environment will decrease with increasing temperature of the environment. In more preferred embodiments of this class, the temperature of the downhole environment is at least 100° C. In the most preferred embodiments of this type, the temperature of the downhole environment is at least 120° C.
EXAMPLE
[0091] The currently preferred embodiments of the invention will be understood better in the context of a specific example. It is to be understood that the example is being provided without reducing the generality of the invention. Persons skilled in the art can readily imagine many additional examples that fall within the scope of the currently preferred embodiments as taught in the DETAILED DESCRIPTION OF THE INVENTION section. Persons skilled in the art can, furthermore, also readily imagine many alternative embodiments that fall within the full scope of the invention as taught in the SUMMARY OF THE INVENTION section.
[0000] A. Summary
[0092] The thermoset matrix was prepared from a formulation containing 20% DVB by weight of the starting monomer mixture. The DVB had been purchased as a mixture where only 63% by weight consisted of DVB. The actual polymerizable monomer mixture used in preparing the thermoset matrix consisted of roughly 68.73% S, 11.27% EVB and 20% DVB by weight.
[0093] Suspension polymerization was performed in a pilot plant reactor, via rapid rate polymerization as taught by Albright (U.S. Pat. No. 6,248,838) which is incorporated herein by reference in its entirety. The “single initiator” approach was utilized in applying this method. The “as-polymerized” particles obtained from this run of the pilot plant reactor (by removing some of the slurry and allowing it to dry at ambient temperature) are designated as Sample AP.
[0094] Some other particles were then removed from the of the slurry, washed, spread very thin on a tray, and heat-treated for ten minutes at 170° C. in an oven under an unreactive gas (nitrogen) blanket. These heat-treated particles will be designated as Sample IA20mG170C.
[0095] FIG. 3 provides a process flow diagram depicting the preparation of the example. It contains four major blocks; depicting the preparation of the aqueous phase (Block A), the preparation of the organic phase (Block B), the mixing of these two phases followed by suspension polymerization (Block C), and the further process steps used after polymerization to obtain the “as-polymerized” and “heat-treated” samples of particles (Block D).
[0096] Particles from each of the two samples were then sent to independent testing laboratories. Differential scanning calorimetry (DSC) was performed on each sample by Impact Analytical, in Midland, Michigan. The liquid conductivities of packings of the particles of each sample were measured by FracTech Laboratories, in Surrey, United Kingdom.
[0097] The following subsections will provide further details on the formulation, preparation and testing of this working example, to enable persons who are skilled in the art to reproduce the example.
[0000] B. Formulation
[0098] An aqueous phase and an organic phase must be prepared prior to suspension polymerization. The aqueous phase and the organic phase, which were prepared in separate beakers and then used in the suspension polymerization of the particles of this example, are described below.
[0099] 1. Aqueous Phase
[0100] The aqueous phase used in the suspension polymerization of the particles of this example, as well as the procedure used to prepare the aqueous phase, are summarized in TABLE 1.
TABLE 1 The aqueous phase was prepared by adding Natrosol Plus 330 and gelatin (Bloom strength 250) to water, heating to 65° C. to disperse the Natrosol Plus 330 and the gelatin in the water, and then adding sodium nitrite and sodium carbonate. Its composition is listed below. INGREDIENT WEIGHT (g) % Water 1493.04 98.55 Natrosol Plus 330 (hydroxyethylcellulose) 7.03 0.46 Gelatin (Bloom strength 250) 3.51 0.23 Sodium Nitrite (NaNO 2 ) 4.39 0.29 Sodium Carbonate (Na 2 CO 3 ) 7.03 0.46 Total Weight in Grams 1515.00 100.00
[0101] 2. Organic Phase
[0102] The organic phase used in the suspension polymerization of the particles of this example, as well as the procedure used to prepare the organic phase, are summarized in TABLE 2.
TABLE 2 The organic phase was prepared by placing the monomers and benzoyl peroxide (an initiator) together and agitating the resulting mixture for 15 minutes. Its composition is listed below. After taking the other components of the 63% DVB mixture into account, the polymerizable monomer mixture actually consisted of roughly 68.73% S, 11.27% EVB and 20% DVB by weight. The total polymerizable monomer weight of was 1355.9 grams. INGREDIENT WEIGHT (g) % Styrene (pure) 931.90 67.51 Divinylbenzene (63% DVB, 430.44 31.18 98.5% polymerizable monomers) Benzoyl peroxide (75% active) 18.089 1.31 Total Weight in Grams 1380.429 100.00
C. Preparation of Particles from Formulation
[0103] Once the formulation is prepared, its aqueous and organic phases are mixed, polymerization is performed, and “as-polymerized” and “heat-treated” particles are obtained, as described below.
[0104] 1. Mixing
[0105] The aqueous phase was added to the reactor at 65° C. The organic phase was introduced 15 minutes later with agitation at the rate of 90 rpm. The mixture was held at 65° C. with stirring at the rate of 90 rpm for 11 minutes, by which time proper dispersion had taken place as manifested by the equilibration of the droplet size distribution.
[0106] 2. Polymerization
[0107] The temperature was ramped from 65° C. to 78° C. in 10 minutes. It was then further ramped from 78° C. to 90° C. very slowly over 80 minutes. It was then held at 90° C. for one hour to provide most of the conversion of monomer to polymer, with benzoyl peroxide (half life of one hour at 92° C.) as the initiator. The actual temperature was monitored throughout the process. The highest actual temperature measured during the process (with the set point at 90° C.) was 93° C. The thermoset polymer particles were thus obtained in an aqueous slurry which was then cooled to 40° C. FIG. 4 shows the variation of the temperature with time during polymerization.
[0108] 3. “As-Polymerized” Particles
[0109] The “as-polymerized” sample obtained from the run of the pilot plant reactor described above will be designated as Sample AP. In order to complete the preparation of Sample AP, some of the aqueous slurry was poured onto a 60 mesh (250 micron) sieve to remove the aqueous reactor fluid as well as any undesirable small particles that may have formed during polymerization. The “as-polymerized” beads of larger than 250 micron diameter obtained in this manner were then washed three times with warm (40° C. to 50° C.) water and allowed to dry at ambient temperature. A small quantity from this sample was sent to Impact Analytical for DSC experiments.
[0110] Particles of 14/16 U.S. mesh size were isolated from Sample AP by some additional sieving. This is a very narrow size distribution, with the particle diameters ranging from 1.19 mm to 1.41 mm. This nearly monodisperse assembly of particles was sent to FracTech Laboratories for the measurement of the liquid conductivity of its packings.
[0111] After the completion of the liquid conductivity testing, the particles used in the packing that was exposed to the most extreme conditions of temperature and compressive stress were recovered and sent to Impact Analytical for DSC experiments probing the effects of the conditions used during the conductivity experiments on the thermal properties of the particles.
[0112] 4. “Heat-Treated” Particles Postcured in Nitrogen
[0113] The as-polymerized particles were removed from some of the slurry. These particles were then poured onto a 60 mesh (250 micron) sieve to remove the aqueous reactor fluid as well as any undesirable small particles that may have formed during polymerization. The “as-polymerized” beads of larger than 250 micron diameter obtained in this manner were then washed three times with warm (40° C. to 50° C.) water, spread very thin on a tray, and heat-treated isothermally for twenty minutes at 170° C. in an oven in an inert gas environment (nitrogen). The heat-treated particles that were obtained by using this procedure will be designated as Sample IA20mG 170C. A small quantity from this sample was sent to Impact Analytical for DSC experiments.
[0114] Particles of 14/16 U.S. mesh size were isolated from Sample IA20mG170C by some additional sieving. This is a very narrow size distribution, with the particle diameters ranging from 1.19 mm to 1.41 mm. This nearly monodisperse assembly of particles was sent to FracTech Laboratories for the measurement of the liquid conductivity of its packings.
[0115] After the completion of the liquid conductivity testing, the particles used in the packing that was exposed to the most extreme conditions of temperature and compressive stress were recovered and sent to Impact Analytical for DSC experiments probing the effects of the conditions used during the conductivity experiments on the thermal properties of the particles.
[0000] D. Differential Scanning Calorimetry
[0116] DSC experiments (ASTM E1356-03) were carried out by using a TA Instruments Q100 DSC with nitrogen flow of 50 mL/min through the sample compartment. Roughly eight to ten milligrams of each sample were weighed into an aluminum sample pan, the lid was crimped onto the pan, and the sample was then placed in the DSC instrument. The sample was then scanned from 5° C. to 225° C. at a rate of 10° C. per minute. The instrument calibration was checked with NIST SRM 2232 indium. Data analysis was performed by using the TA Universal Analysis V4.1 software.
[0117] The DSC data are shown in FIG. 5 . Sample AP manifests a large exothermic curing peak region 510 instead of a glass transition region when it is heated. Sample AP is, hence, partially (and in fact only quite poorly) cured. On the other hand, while the DSC curve of Sample IA20mG 170C 520 is too featureless for the software to extract a precise glass transition temperature from it, there is no sign of an exothermic peak. Sample IA20mG 170C is, hence, very well-cured. The DSC curves of Sample AP/406h6000psi 530 and Sample IA20mG170C/406h6000psi 540, which were obtained by exposing Sample AP and Sample IA20mG170C, respectively, to 406 hours of heat at a temperature of 250° F. under a compressive stress of 6000 psi during the liquid conductivity experiments described below, are also shown. Note that the exothermic peak is missing in the DSC curve of Sample AP/406h6000psi, demonstrating that “in situ” postcuring via heat treatment under conditions simulating a downhole environment has been achieved. For the purposes of this application the term “substantially cured” means the absence of an exothermic curing peak in the DSC plot.
[0000] E. Liquid Conductivity Measurement
[0118] A fracture conductivity cell allows a particle packing to be subjected to desired combinations of compressive stress (simulating the closure stress on a fracture in a downhole environment) and elevated temperature over extended durations, while the flow of a fluid through the packing is measured. The flow capacity can be determined from differential pressure measurements. The experimental setup is illustrated in FIG. 6 .
[0119] Ohio sandstone, which has roughly a compressive elastic modulus of 4 Mpsi and a permeability of 0.1 mD, was used as a representative type of outcrop rock. Wafers of thickness 9.5 mm were machined to 0.05 mm precision and one rock was placed in the cell. The sample was split to ensure that a representative sample is achieved in terms of its particle size distribution and then weighed. The particles were placed in the cell and leveled. The top rock was then inserted. Heated steel platens were used to provide the correct temperature simulation for the test. A thermocouple inserted in the middle port of the cell wall recorded the temperature of the pack. The packings were brought up to the targeted temperature gradually and equilibrated at that temperature. Consequently, many hours of exposure to elevated temperatures had already taken place by the inception of the collection of conductivity data points, with the time at which the fully equilibrated cells were obtained being taken as the time=zero reference. A servo-controlled loading ram provided the closure stress. The conductivity of deoxygenated silica-saturated 2% potassium chloride (KCl) brine of pH 7 through the pack was measured.
[0120] The conductivity measurements were performed by using the following procedure:
[0000] 1. A 70 mbar full range differential pressure transducer was activated by closing the bypass valve and opening the low pressure line valve.
[0000] 2. When the differential pressure appeared to be stable, a tared volumetric cylinder was placed at the outlet and a stopwatch was started.
[0000] 3. The output of the differential pressure transducer was fed to a data logger 5-digit resolution multimeter which logs the output every second during the measurement.
[0121] 4. Fluid was collected for 5 to 10 minutes, after which time the flow rate was determined by weighing the collected effluent. The mean value of the differential pressure was retrieved from the multimeter together with the peak high and low values. If the difference between the high and low values was greater than the 5% of the mean, the data point was disregarded.
[0122] 5. The temperature was recorded from the inline thermocouple at the start and at the end of the flow test period. If the temperature variation was greater than 0.5° C., the test was disregarded. The viscosity of the fluid was obtained from the measured temperature by using viscosity tables. No pressure correction is made for brine at 100 psi. The density of brine at elevated temperature was obtained from these tables.
[0123] 6. At least three permeability determinations were made at each stage. The standard deviation of the determined permeabilities was required to be less than 1% of the mean value for the test sequence to be considered acceptable.
[0124] 7. The end of the permeability testing, the widths of each of the four corners of the cell were determined to 0.01 mm resolution by using vernier calipers.
[0125] The test results are summarized in TABLE 3.
TABLE 3 Measurements on packings of 14/16 U.S. mesh size of Sample AP and Sample IA20mG170C at a coverage of 0.02 lb/ft 2 . The conductivity of deoxygenated silica-saturated 2% potassium chloride (KCl) brine of pH 7 through each sample was measured at a temperature (T) of 190° F. (87.8° C.) under a compressive stress (□ c ) of 4000 psi (27.579 MPa), at a temperature of 220° F. (104.4° C.) under a compressive stress of 5000 psi (34.474 MPa), and at a temperature of 250° F. (121.1° C.) under a compressive stress of 6000 psi (41.369 MPa). The time (t) is in hours. The liquid conductivity (J) is in mDft. T = 220° F., □ c = 5000 psi J of T = 250° F., □ c = 6000 psi t J of AP IA20mG170C t J of AP J of IA20mG170C 29 558 669 22 232 225 61 523 640 46 212 199 113 489 584 70 198 187 162 468 562 118 154 176 213 455 540 182 142 159 259 444 527 230 137 147 325 418 501 264 135 145 407 390 477 326 128 145 357 122 139 379 120 139 406 118 137
[0126] These results are shown in FIG. 7 .
[0127] The liquid conductivity of the partial monolayer of the heat-treated particles under a closure stress of 5000 psi at a temperature of 220° F. is seen to be distinctly higher than that of the partial monolayer of the “as polymerized” particles that were postcured via “in situ” heat treatment in the conductivity cell at a temperature of only 220° F.
[0128] It is also seen that partial monolayers of both particles that were heat-treated in a discrete additional post-polymerization process step and “as polymerized” particles that were kept for a prolonged period in the elevated temperature environment of the conductivity cell manifest useful levels of liquid conductivity (above 100 mDft) even under a closure stress of 6000 psi at a temperature of 250° F. The difference in liquid conductivity between the partial monolayers of these two types of particles is very small under a closure stress of 6000 psi at a temperature of 250° F., where long-term exposure to this rather high temperature is highly effective in advancing the postcuring of the “as polymerized” particles via “in situ” heat treatment as was shown in FIG. 5 .
[0129] The present disclosure may be embodied in other specific forms without departing from the spirit or essential attributes of the disclosure. Accordingly, reference should be made to the appended claims, rather than the foregoing specification, as indicating the scope of the disclosure. Although the foregoing description is directed to the preferred embodiments of the disclosure, it is noted that other variations and modification will be apparent to those skilled in the art, and may be made without departing from the spirit or scope of the disclosure. | Thermoset polymer particles are used in many applications requiring lightweight particles possessing high stiffness, strength, temperature resistance, and/or resistance to aggressive environments. The present invention relates to the use of methods to enhance the stiffness, strength, maximum possible use temperature, and environmental resistance of such particles. One method of particular interest is the application of post-polymerization process step(s) (and especially heat treatment) to advance the curing reaction and to thus obtain a more densely crosslinked polymer network. The most common benefits of said heat treatment are the enhancement of the maximum possible use temperature and the environmental resistance. The present invention also relates to the development of thermoset polymer particles. It also relates to the further improvement of the key properties (in particular, heat resistance and environmental resistance) of said particles via post-polymerization heat treatment. Furthermore, it also relates to processes for the manufacture of said particles. Finally, it also relates to the use of said particles in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells; for example, as a proppant partial monolayer, a proppant pack, an integral component of a gravel pack completion, a ball bearing, a solid lubricant, a drilling mud constituent, and/or a cement additive. | 8 |
INTRODUCTION AND BACKGROUND
The present invention relates to aqueous solutions of polymeric organosiloxane-ammonium compounds which possess ion exchange properties and a method for their manufacture and use.
Polymeric organosiloxane-ammonium compounds of this kind are known in solid form from DE 38 00 564 (U.S. Pat. Nos. 5,130,396 and 5,239,033). In DE 31 20 195 (U.S. Pat. No. 4,410,669), the polymeric ammonium compounds are soluble in hot water at a pH of 7 in the case of 2 Si atoms per quaternized N atom; however, at room temperature the polymers precipitate. The polymeric ammonium compounds of DE 31 20 195 are totally insoluble in hot water in the case of 3 or 4 Si atoms per quaternized N atom. The presence of such polymeric organosiloxane-ammonium compounds in solid form (fine-particle, spherical) limits severely, however, the possible uses of these polymers containing a silica type skeleton.
SUMMARY OF THE INVENTION
An object of the present invention is the production of aqueous solutions of ion exchangers which are suitable for treating inorganic materials or building materials. The present invention provides alkaline aqueous solutions of polymeric silicon-containing ion exchangers which consist of units with the following formula ##STR1## in which R 1 and R 2 are the same or different and signify a group with the general formula ##STR2## wherein the nitrogen atoms in (I) are connected via the residues R 5 with the silicon atoms in (II) and the free valences of O are partially or completely saturated by H or by alkali metal ions and R 5 represents an alkylene group with 1 to 10 C atoms, a cycloalkylene group with 5 to 8 C atoms or a unit with the general formula ##STR3## in which n is a number from 1 to 6 and indicates the number of methylene groups in the nitrogen position and m is a number from 0 to 6,
wherein the free valences of the oxygen atoms bonded to the silicon atom are, as with silica skeletons, saturated by silicon atoms of further groups of formula (II) and/or with the metal atoms of one or more of the crosslinking bridge members (III) ##STR4## wherein M is a silicon, titanium or zirconium atom and R' is a linear or branched alkyl group with 1 to 5 C atoms, and the ratio of the silicon atoms from the groups of general formula (II) to the metal atoms in the bridge members (III) is 1:0 to 1:10, in which R 3 is equal to R 1 or R 2 or hydrogen, a linear or branched alkyl group of 1 to 20 C atoms, or a cycloalkyl group consisting of 5 to 6 C atoms, and R 4 represents hydrogen, a linear or branched alkyl group with 1 to 20 C atoms or a cycloalkyl group consisting of 5 to 8 C atoms, X corresponds to an anion, in particular OH - , and x to a number from 1 to 3.
DETAILED DESCRIPTION OF THE INVENTION
According to a more detailed aspect of the invention, preferred compounds which are present in the solution are those in which R 5 corresponds to a propylene group.
Particularly suitable are also those in which R 1 , R 2 and R 3 are identical and R 4 corresponds to a methyl group.
A preferably used educt is
((CH.sub.3)N((CH.sub.2).sub.3 Si(OH).sub.y (OM).sub.y-3).sub.3).sub.x.sup.x+
distinguished in solution by the formula
((CH.sub.3)N((CH.sub.2).sub.3 Si(OH.sub.y)(OM).sub.y-3).sub.3).sub.x.sup.x+,
with y=0, 1, 2, or 3, and M is an alkali metal ion.
Critical for the solubility is the number of groups of formula (II) bonded to nitrogen. If only R 1 and R 2 are of the formula (II) type, a better solubility of the polymer exists, and hence a higher concentration of the soluble organosiloxane-ammonium compounds, than in cases where three substituents on the nitrogen are of the (II) type.
Consequently, the possible concentration of dissolved siloxane also covers a wide range from 0.1 to 70 wt%. Lower concentrations are naturally possible, but because of the low active substance content they are relevant to only a limited extent. Highly viscous fluids are obtained in the upper concentration range which in certain circumstances are still fluid only at elevated temperature (˜40°-100° C.), but which set like glass at room temperature. These then solid substances can be dissolved without difficulty in water, optionally with boiling. A preliminary comminution of the solid by crushing or grinding may be advisable.
Particularly favorable is a content of 5-30 wt% of siloxane-ammonium compounds in the aqueous solution, since the content is sufficiently high for commercial application, but the solutions can still be handled easily and applied to surfaces by pouring, spraying or dipping.
For the stability of the aqueous solution against unwanted solids precipitation, a content of alkali hydroxide of at least 1.5 times the mole quantity, of Si atoms present in the organosiloxane-ammonium compound according to formula (I) plus the optionally present molar quantities of Si-, Ti-, Zr- or Al-containing crosslinkers is advantageous. Higher concentrations of alkali hydroxide are naturally also possible, so that the alkali hydroxide content in the solution can lie between 0.01 and 50 wt%. The lowest possible base concentrations are naturally aimed at for the commercial applications. In the solution according to the invention the oxygen atoms in the groups of formula (II) can be partially or completely saturated by alkali metals or hydrogen or partially saturated by silicon, titanium, zirconium, aluminum or other metals which are contained in the organopolysiloxanes, as described in the cited patent specifications, on which the solution is based (U.S. Pat. No. 5,130,396; 5,239,033 and 4,410,669 are incorporated by reference in their entirety). Organo-silicic acids or organo-silicates can therefore exist in solution as monomers or oligomers.
Unlike U.S. Pat. No. 4,410,669, the solutions according to the invention with 2 or 3 Si atoms per quaternized N atom can be formed at room temperature at higher concentrations with ammonium compounds when the pH value is greater than 7; in other words, the solutions are not neutral, they are aqueous alkaline solutions.
In the method for manufacturing the solutions according to the invention, a hydrolysis of the polysiloxane skeleton takes place so that soluble organosilanolate units are obtained from the insoluble, highly crosslinked siloxane matrix.
As is known, the units according to formula (I) can as a function of their concentration in aqueous solution also be present as soluble oligomers, in which at least two molecules are bonded to one another via a siloxane bridge. If the concentration of an aqueous solution of compounds of formula (I) were to be increased beyond the limit of 70 wt% determined as critical, structures of higher molecular weight would however be obtained, which precipitate out of the solution as solids. This process is however reversible by the addition of water, so that for particular applications of these organosilicon compounds in principle a corresponding suspension can also be used.
Oligomers, i.e. condensed derivatives, which are present in equilibrium with the corresponding monomers in solution, as a function of e.g. concentration, alkali content and temperature, can have e.g. the following structure ##STR5## wherein as a function of the alkali content of the solution some or all of the hydrogen atoms or ions of the OH groups in the Si position are replaced by alkali metal atoms or ions.
Depending on the starting compound of formula (I) used, there can be present in the alkaline, aqueous solution of the silicon-containing ion exchangers optionally also monomers or oligomeric silicon, titanium, zirconium or aluminum units, which result from a partial or complete hydrolysis of the siloxane or heterosiloxane skeleton of the bridge members according to formula (III) functioning as crosslinkers. As a function of e.g. concentration, alkali content or temperature, these crosslinkers can be present as monomeric silicate, titanate, zirconate or aluminate units, e.g. with the structure
H.sub.3 C-Si(OH).sub.3 or H.sub.3 C-Si(OH).sub.2 (ONa)
or H.sub.3 C-Si(OH)(ONa).sub.2 or H.sub.3 C-Si(ONa).sub.3,
or however also as oligomeric derivatives condensed individually on their own, e.g. H 3 C-Si(ONa) 2 -O-Si(ONa) 2 - CH 3 , or as derivatives fused to hydrolyzed monomeric or oligomeric units according to formula (I).
The invention likewise provides a method for manufacturing solutions described above, characterized in that formed or unformed polymeric, crosslinked organosiloxane-ammonium compounds with a silica type skeleton, consisting of units with the general formula ##STR6## in which R 1 or R 2 are the same or different and signify a group with the general formula ##STR7## wherein the nitrogen atoms in (I) are connected via the residues R 5 with the silicon atoms in (II) and R 5 represents an alkylene group with 1 to 10 C atoms, a cycloalkylene group with 5 to 8 C atoms or a unit with the general formula ##STR8## in which n is a number from 1 to 6 and indicates the number of methylene groups in the nitrogen position and m is a number from 0 to 6, wherein the free valences of the oxygen atoms bonded to the silicon atom are, as with silica skeletons, saturated by silicon atoms of further groups of formula (II) and/or with the metal atoms of one or more of the crosslinking bridge members (III) ##STR9## wherein M is a silicon, titanium or zirconium atom, and R' is a linear or branched alkyl group with 1 to 5 C atoms, and the ratio of the silicon atoms from the groups of general formula (II) to the metal atoms in the bridge members (III) is 1:0 to 1:10, and in which R 3 is equal to R 1 or R 2 or hydrogen, a linear or branched alkyl group of 1 to 20 C atoms, a cycloalkyl group consisting of 5 to 6 C atoms or the benzyl group, and R 4 represents likewise hydrogen, a linear or branched alkyl group with 1 to 20 C atoms or a cycloalkyl group consisting of 5 to 8 C atoms,
X is an anion with the valency of x equal to 1 to 3, preferably from the halide or sulphate group, are converted into the hydroxide optionally by repeated washing, preferably at room temperature, with a 0.01 to 1 molar, preferably 0.1 to 0.5 molar, aqueous alkali hydroxide solution (e.g., KOH, LiOH, NaOH). After this, it is washed neutral and X-anions-free and then treated with an alkali hydroxide (e.g., KOH, LiOH, NaOH) in water at a temperature between 40° and 200° C., preferably 60° and 100° C., optionally under a pressure arising in this system, until the solid polymer used has dissolved.
As a rule it is sufficient to reflux with 0.5-2 times the molar quantity of alkali hydroxide, based on the quantity of Si atoms present in the polymer used plus the molar quantity of Si-, Ti-, Zr- or Al-containing crosslinkers optionally present.
It is possible to intensify the solution effect by the addition of auxiliary substances which prevent renewed fusing of the silanol groups, such as e.g. ethylene glycol. Similarly, bases can also be used in excess in order to accelerate the solution process, which is then subsequently partly neutralized.
Depending on the amount of polysiloxane to be dissolved, only a very short time of a few minutes can be sufficient, but it may also however become necessary to dissolve the polysiloxane in alkaline material over a longer period, optionally with the re-charging of the alkaline material or polysiloxane. If the solution is manufactured in a pressure vessel, higher temperatures up to 200° C. can be used, at pressures which correspond to the sum of the partial pressures of the components present. This can be advantageous for the acceleration of the solution process. As regards the composition of the aqueous polysiloxane-ammonium solution, the form of use of the polysiloxane according to formula (I) is critical. In order to avoid the presence of undesirable anions in the solution, it is advantageous, prior to the actual dissolving, to first of all convert the solid ammonium-polysiloxane compound into the desired form by an ion exchange.
A system which is of extraordinary importance on grounds of commercial availability is the aqueous solution of
((H.sub.3 C)N(CH.sub.2 CH.sub.2 CH.sub.2 SiO.sub.3/2).sub.3).sup.+ OH.sup.31
used as a solid compound. It is surprising that with this system stable solutions, not gelling or precipitating solids, are also present, which exhibit in the form used typically a polysiloxane content of 5-30 wt%, referred to the total quantity of the solution, but have only an alkali metal ion content of typically 1-5 wt% based on the total quantity of the solution.
EXAMPLE 1
347 g of the solid polysiloxane with the composition
(H.sub.3 C-N(CH.sub.2 CH.sub.2 CH.sub.2 SiO.sub.3/2).sub.3).sup.+ Cl.sup.31
are first of all converted into the hydroxide form by repeated washing with a total of 20 l 0.1 M NaOH and after this are washed neutral and chloride-free. The solid is dissolved with 1.0 l 2 M NaOH at 80° C. in 2 hours. The clear solution obtained is cooled and diluted to 2.0 l, so that a usable solution is obtained which is 1.0 M of NaOH (approx. 3 wt%) and 0.5 M of ammonium polysiloxane (approx. 13 wt%)(wt% based on the total amount of the solution).
EXAMPLE 2
347 g of the polysiloxane as in Example 1 are dissolved directly in 0.5 l 4 M LiOH and 0.25 l water at 95° C. in 1.5 hours, cooled and diluted to 1.0 l. The clear solution obtained is 2.0 M of LiOH (approx. 3.5 wt%) and 1.0 M of ammonium polysiloxane (approx. 23 wt%).
Further variations and modifications of the foregoing will be apparent to those skilled in the art and such variations and modifications are attended to be encompassed by the claims that are appended hereto. | Disclosed are aqueous solutions of polymeric organosiloxane-ammonium compounds which possess ion exchange properties and a method for manufacture from solid organopolysiloxanes. The solutions are used in the hydrophobing treatment of inorganic materials and building materials. | 2 |
RELATED APPLICATION
This application claims priority from U.S. Provisional Application 60/130,893 filed Apr. 23, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to devices and methods for controlling the delivery and the delivery direction of an aerosol, and particularly to a method and apparatus for induced aerosol flow in an electrohydrodynamic (EHD) sprayer.
2. Background
The use of electrohydrodynamic (EHD) apparatus to produce aerosols is well known. Recently, we have recognized that EHD devices are extremely useful to produce and deliver aerosols of therapeutic products.
In typical EHE) devices fluid delivery means deliver fluid to be aerosolized to a nozzle maintained at high electric potential. One type of nozzle used in EHD devices is a capillary tube that is capable of conducting electricity. An electric potential is placed on the capillary tube which charges the fluid contents such that as the fluid emerges from the tip or end of the capillary tube a so-called Taylor cone is formed. This cone shape results from a balance of the forces of electric charge on the fluid and the fluid's own surface tension. Desirably, the charge on the fluid overcomes the surface tension and at the tip of the Taylor cone, a thin jet of fluid forms and subsequently and rapidly separates a short distance beyond the tip into an aerosol. Studies have shown that this aerosol (often described as a soft cloud) has a fairly uniform droplet size and a high velocity leaving the tip but that it quickly decelerates to a very low velocity a short distance beyond the tip.
EHD sprayers produce charged droplets at the tip of the nozzle. Depending on the use, these charged droplets can be partially or fully neutralized (with a reference or discharge electrode in the sprayer device) or not. The typical applications for an EHD sprayer without means for discharging or means for partially discharging an aerosol would include a paint sprayer or insecticide sprayer. These types of sprayers may be preferred since the aerosol would have a residual electric charge as it leaves the sprayer so that the droplets would be attracted to and tightly adhere to the surface being coated. However, with EHD apparatus used to deliver therapeutic aerosols, it is preferred that the aerosol be completely electrically neutralized prior to inhalation by the user to permit the aerosol to reach the pulmonary areas where the particular therapeutic formulation is most effective.
The preferred orientation of EHD sprayers is with the nozzle vertical and located above the object to receive the aerosol. This nozzle orientation eliminates, for practical purposes, the problems associated with the fluid dispensed from the nozzle tip collecting on or wicking up the outside of the capillary tube and associated fluid delivery means. If the fluid flows up the outside of the nozzle from the tip, it is no longer available to be sprayed and represents a loss in efficiency of the device. Moreover, fluid on the outside surfaces of the capillary tube may accumulate and suddenly flow back to the tip where it may disrupt the Taylor cone. These disruptions and any other disruptions of the Taylor cone may result in a large variation in the size and size distribution of the aerosol droplets which is particularly undesirable in pulmonary drug delivery.
When administering pharmaceuticals to a patient these limitations on orientation of the EHD apparatus result in either the patients having to tilt their head backwards or to lie on their back when the aerosol is delivered on axis with the nozzle. Alternatively, the EHD apparatus can deliver the aerosol vertically on axis with the nozzle and an elbow means can change the direction of aerosol flow to deliver the aerosol nearly horizontally. With this change in direction of the aerosol, there often is an appreciable loss in the quantity of the aerosol. The loss in quantity is a result of the fluid impacting and depositing on the walls of the delivery device, particularly in the vicinity of the elbow, instead of reaching the patient. One device for reducing disruptions of the Taylor cone and for reducing the loss in quantity of fluid impacting the walls is described in a co-owned U.S. patent application filed of even date herewith and entitled “High Mass Transfer EHD Aerosol Sprayer”, which application is hereby incorporated by reference. Therefore, an EHD aerosol sprayer is needed where the aerosol delivery direction can be controlled and wherein the Taylor cone can be stabilized to prevent disruption. Of particular need, is an EHD aerosol sprayer that can spray substantially horizontally and deliver the aerosol without appreciable wetting of the delivery device.
SUMMARY OF THE INVENTION
The invention described herein provides an aerosol delivery method and system for solving the problems discussed above by producing a charged EHD aerosol, discharging the aerosol and inducing a flow in the discharged aerosol in a desired direction without substantial wetting of the device.
In a preferred embodiment the delivery system includes a spray nozzle for dispensing the fluid to be aerosolized and negatively charging the aerosol droplets, a discharge electrode generally proximate the spray nozzle for generating a positive ion stream which intercepts and electrically neutralizes the negative aerosol droplets while also imparting a desired movement on the aerosol in a direction generally away from the discharge electrode, and at least one first reference electrode between the spray nozzle and the discharge electrode for modifying the electric field between the spray nozzle and the discharge electrode. Preferably, the discharge electrode is positioned proximate the spray nozzle such that the ion cloud intercepts the aerosol at a short distance, for example less than about 4 centimeters and more preferably less than 2 centimeters from the spray nozzle tip before the aerosol cloud has had a chance to disperse to a large degree.
Optionally, at least one second reference electrode may be placed near the discharge electrode on the side opposite of the first electrode. Optionally, at least one third electrode may also be placed near the spray nozzle on the side opposite the first reference electrode.
The spray nozzle is usually placed at a potential of between one and twenty kilovolts, with three to six kilovolts being the preferred voltage range. The placing of a negative potential on the spray nozzle results in the aerosol being negatively charged. To electrically discharge the aerosol, a positive potential of between one and twenty kilovolts, and with a preferred voltage of three to six kilovolts, is placed on a discharge electrode. The charges could be reversed on the spray nozzle and the discharge electrode, however, the positive ions from the discharge electrode appear to be much more effective than would negative ions in imparting movement (induced flow) to the aerosol.
Preferably, the discharge electrode includes a sharp point or edge where a positively charged ion cloud is originated to discharge the aerosol and move it in the desired direction. In a preferred embodiment, the axis of the spray nozzle and the axis of the discharge electrode are at an angle of less than about 120 degrees (between 0 degrees and 180 degrees) and more preferably in the range of 30-90 degrees. Larger angles may also be useful, but at angles approaching 180 degrees (the electrodes thereby being substantially opposed) the movement of the aerosol would be substantially toward the spray nozzle. In most uses, this would not be desirable to direct the charged aerosol substantially toward the discharge electrode, as the droplets are readily attracted to the electrode surface which reduces the aerosol delivery efficiency of the sprayer. If the discharge electrode becomes wetted with aerosol under these conditions, an undesired secondary spray can result at the discharge electrode. It is also undesirable to direct the discharge ion cloud substantially toward the spray nozzle as these ions can disrupt the EHD aerosol generation process.
Between the spray nozzle and the discharge electrode is a first reference electrode. The first reference electrode may be a wire, screen, plate or tube, but preferably has a shape that may influence an air stream to move past the spray nozzle. The first electrode may be on but one side of the spray nozzle near the discharge electrode or it may substantially surround the spray nozzle. Preferably, the first reference electrode intersects or breaks the line of sight between the tip of the nozzle and the tip of the discharge electrode to some what de-couple the nozzle's electric field from the electric field of the discharge electrode. By somewhat de-coupling these two electric fields, the attraction of the negatively charged aerosol to the positively charged discharge electrode is minimized. Consequently, the discharge electrode remains predominantly dry. Thus, the accumulation of the aerosol on the discharge electrode does not present a problem from the standpoint of reducing the quality and quantity of the aerosol delivered to the user.
The EHD device is constructed such that gas (generally air) is allowed to enter the device and to then flow near the spray nozzle toward the tip and past the Taylor cone. This gas flow has been found to stabilize the Taylor cone and to move the aerosol away from the tip of the spray nozzle. Moving the charged aerosol away from the tip seems to aid the aerosolization phenomenon at the Taylor cone. Preferably, the corona wind from the discharge electrode is used to assist in inducing the gas flow over the Taylor cone. The positively charged ion cloud downstream from the spray tip readily attracts the negatively charged aerosol droplets away from the nozzle. The motion of the aerosol droplets also induces gas flow over the spray tip and over the Taylor cone.
A preferred embodiment of the delivery method includes dispensing a fluid through a negatively charged spray nozzle to produce negatively charged aerosol droplets by the EHD process, generating a positive ion stream from a positively charged discharge electrode generally proximate the spray nozzle such that the ion stream intercepts and electrically neutralizes the negative aerosol droplets downstream of the spray nozzle while also imparting a desired movement on the aerosol in a direction generally away from the discharge electrode, and inserting a reference electrode between the spray nozzle and the discharge electrode for modifying the electric field between the spray nozzle and the discharge electrode. Preferably, the method further includes orienting the axis of the spray nozzle and the axis of the discharge electrode at an angle of less than about 120 degrees and more preferable in the range of 30-90 degrees. Preferably, the ion cloud intercepts the aerosol at a short distance, for example less than about 4 centimeters and more preferably less than 2 centimeters, from the spray nozzle tip before the aerosol cloud has had a chance to disperse to a large degree.
Another preferred embodiment of the delivery method includes dispensing a fluid through a negatively charged spray nozzle to produce negatively charged aerosol droplets from a Taylor cone in an EHD process, generating a positive ion stream around a positively charged discharge electrode generally proximate the spray nozzle such that the ion stream intercepts and electrically neutralizes the negative aerosol droplets downstream of the spray nozzle while also imparting a desired movement on the aerosol in a direction generally away from the discharge electrode, inserting a first reference electrode between the spray nozzle and the discharge electrode for modifying the electric field between the spray nozzle and the discharge electrode, providing a gas flow path near the Taylor cone between the spray nozzle and the first reference electrode and inducing gas flow past the spray nozzle along the gas flow path.
The EHD apparatus and method is a preferred application of the invention wherein the aerosol is charged. As described earlier, however, the invention is also useful for delivery of many other aerosol products (e.g. fragrances, lubricants, etc). In these other uses it may be useful to move an uncharged aerosol. In this case, the discharge electrode described herein may more accurately be termed an “ionization electrode” because the ions do not discharge the charge on the aerosol, but merely provide the momentum or the corona wind to direct the flow in the desired direction. Apparatus according to the invention would include aerosol source, an ionization electrode for developing the corona wind along a desired path, a reference electrode and a voltage source.
In any of the applications of the invention the corona wind could either be a positive or negative ion stream, though the positive stream seems to have some advantages in the drug delivery applications.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawing incorporated in and forming part of the specification illustrates several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:
FIG. 1 is a schematic of an EHD sprayer in accordance with the present preferred embodiment of the invention.
FIG. 2 is a schematic of an EHD sprayer in accordance with a second embodiment of the invention.
FIG. 3 is a schematic of an EHD sprayer in accordance with a third embodiment of the invention
FIG. 4 is an orthographic cutaway view of a multi-nozzle EHD sprayer in accordance with the present invention.
FIG. 5 is a side view of the multi-nozzle sprayer shown in FIG. 4 taken at 5 — 5 .
FIG. 6 is a front view of the multi-nozzle sprayer shown in FIG. 4 .
FIGS. 7A and 7B show cross sectional views of preferred spray tips used in delivering fluid to an EHD sprayer.
Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention includes methods and apparatus for directionally controlling the delivery of an aerosol along a desired path. The aerosol may be created by any number of known means (for example, by vaporization, nebulization, electrospraying, expansion through an orifice, and the like) and may have an electrical charge or not. One preferred method of creating the aerosol is by electospraying and particularly by electrohydrodynamic spraying. The purpose of the induced flow electrohydrodynamic (EHD) aerosol sprayer is to provide a device that will permit an operator to consistently spray an aerosol horizontally or in any other arbitrary direction, in the absence of other external airflow. The sprayer utilizes electrical means for stabilizing the Taylor cone with a gas flow near the Taylor cone and for directionally controlling the movement of the charged aerosol generally in a direction controlled by the position and orientation of the discharge electrode and the reference electrode.
The aerosol delivery system and method are particularly useful for delivering therapeutic agents by inhalation. They are even more useful for delivering therapeutic agents into the lungs. Therapeutic agents include any materials that are beneficial to the user. Particularly useful therapeutic agents include not only pharmaceuticals but also, for example, chemotherapeutic or chemopreventive agents, vaccines, nucleic acids, proteins and gene therapy agents.
Though the invention is described in sufficient detail to enable others to practice it, and though not bound to a description of the manner in which the invention works, nevertheless the inventors believe that the movement of the aerosol away from the discharge electrode is due to the effect of what is termed a corona wind or induced air flow. It is believed that the corona wind works in the following way. The positive charge on the discharge electrode results in corona or ionization of the nearby air molecules producing a positive ion cloud around the electrode. The like-charged ions repel and cause a migration of these ionized air molecules away from the discharge electrode. As is well understood in the art, a sharp point or edge on the discharge electrode (which would be one of our preferred embodiments of the discharge electrode) substantially increases the corona and the movement of the ions away from the point or edge. Since these air molecules have mass, their movement causes a corona wind effect or induced air flow directly away from the discharge electrode (rather axially to a sharp point or edge of the discharge electrode), which then intercepts the aerosol droplets downstream of the tip of the nozzle and redirects them (imparts momentum) generally along the path of the corona wind. As earlier noted, the positively charged air molecules also serve to neutralize/discharge the negative charge on the aerosol. Since the corona wind from the discharge electrode moves along the axis of and away from the discharge electrode, the orientation of the discharge electrode substantially determines the direction taken by the aerosol.
By providing an air flow path alongside of the spray nozzle, it has also been found that as the corona wind moves the aerosol away from the spray nozzle, an induced airflow is caused along the spray nozzle and past the Taylor cone. This induced airflow seems to stabilize the Taylor cone, particularly as the EHD device is operated in different orientations. The induced airflow seems to improve the aerosolization process by preventing wicking of the fluid on the outside of the spray nozzle and by transporting the charged aerosol droplets away from the region downstream of the spray nozzle. It may also provide an air curtain that centers the Taylor cone, though this is not proven yet. The induced airflow is beneficial whether the corona wind is created on but one side of the spray nozzle or at several sites or substantially all around the spray nozzle with single or multiple discharge electrodes and reference electrodes.
FIG. 1 provides a schematic of the preferred embodiment of the induced flow EHD aerosol sprayer 10 . In this embodiment, the basic sprayer 10 has housing wall 12 terminating in an exit mouthpiece 8 , a spray nozzle 20 having a central axis 24 , a first reference electrode 40 , and discharge electrode 70 having a central axis 74 . The exit mouthpiece 8 generally has a contour allowing the user to bring the aerosol sprayer into contact with the lips or mouth area and receive the aerosol through the mouth for treatment of the lungs. The DC voltage source 30 electrically connects and maintains the spray nozzle 20 at a negative voltage with respect to reference electrode 40 . A second DC voltage source 60 electrically connects and maintains the discharge electrode 70 at a positive voltage with respect to reference electrode 40 . Ground 50 maintains reference electrode 40 at a ground reference voltage, approximately zero volts DC. It will be understood that the reference electrode 40 is conveniently at ground potential, but that it could be at any potential that is negative with respect to the discharge electrode and positive with respect to the spray nozzle. Moreover, the polarity of the charge on the spray nozzle and discharge electrode are conveniently negative and positive respectively, but it is only necessary that the charges are negative and positive with respect to each other (and the reference electrode).
Spray nozzle 20 is typically a capillary tube or other tube, plate or any other shape used to deliver fluid in EHD applications. In some embodiments the tube used for spray nozzle 20 may have a spray tip 22 which may be designed specifically for EHD spray applications. These tips promote the formation and stability of the Taylor cone. A stable Taylor cone tends to reduce the deviation in the droplet size in the resulting aerosol. The invention includes apparatus including a single spray nozzle that can produce multiple Taylor cones and apparatus with multiple spray nozzles.
One preferred spray nozzle design is shown in FIGS. 7A and 7B. Each spray nozzle 730 includes a round tube having a spray tip 732 at one end and a connection to the source of fluid to be aerosolized at the other end. The spray tip can be merely the open end of the spray nozzle or can optionally include other designs or elements to better promote the formation of Taylor cones. In FIGS. 7A and 7B a partitioning plug 734 is secured in the spray nozzle at the spray tip. The partitioning plug 734 is a cylindrical element terminating in a cone 736 that becomes part of the spray tip for creation of the Taylor cone. The partitioning plug is machined to have four ribs 738 and having therefore a cross section in the shape of a cross to provide four paths for the fluid in the spray nozzle. This has been found to improve the formation of the Taylor cone and to increase the throughput of fluid. Other designs may result in one or more Taylor cones at each spray tip. Multiple nozzles in any useful arrangement may be used in the device.
Discharge electrode 70 typically has a sharp discharge tip 72 or a knife-edge or other sharp points or other protrusions. As is known in the art, these sharp shapes tend to promote the formation of ions. Alternatively, any tip shape that is capable of ionizing air molecules may be utilized. The discharge electrode is generally elongated and has a fairly easily definable central axis 74 . Whether elongated or not, however, the tip 72 will have a geometry which allows significant ionization in the neighborhood of one or more sites on the discharge electrode and movement of the ions away from these sites in a direction which is predictable and reproducible. When the central axis is easily definable, the direction of movement of the ions and ultimately the aerosol is generally parallel with this axis. When the axis is not easily definable, the direction of movement of the ions and the aerosol is predictable and reproducible away from the sites in a direction that we will define as axial to the discharge sites. Discharge electrodes with multiple ionization sites and multiple discharge electrodes (with or without multiple spray nozzles) are within the scope of the invention.
The discharge electrode is located sufficiently close to the spray nozzle 20 and to the spray tip 22 and is oriented with respect thereto such that the ions from the discharge electrode may intercept the aerosol downstream of the spray tip 22 . If the interception point is remote from the spray tip at a point where the aerosol has had sufficient time to become quite disperse, the effect of the ion cloud to move the aerosol in the desired direction is diminished. Therefore, the discharge electrode is preferably located sufficiently close to the spray nozzle 20 and to the spray tip 22 and is oriented with respect thereto such that the ions from the discharge electrode may intercept the aerosol proximate the spray tip 22 before the aerosol has dispersed to any great degree.
A reference electrode 40 is located between spray nozzle 20 and discharge electrode 70 . This reference electrode can be a wire, screen, plate, tube or other shape with modifies the field between the spray nozzle and the discharge electrode. When used for influencing the flow of air near the spray nozzle and the Taylor cone, the reference electrode preferably has a shape and size sufficient for that purpose. In some embodiments, the spray end 42 of reference electrode 40 may be located proximate but not intersecting the line LOS that connects the spray tip 22 to discharge tip 72 . In other embodiments, the spray end 42 of reference electrode 40 may be located to barely intersect the line LOS. In a preferred embodiment, however, the reference electrode 40 is positioned so that it crosses line LOS and the spray end 42 is past the line LOS but not substantially within the region of the aerosol spray downstream of the spray nozzle during use. With the reference electrode in this preferred position, the electric field generated between the spray nozzle 20 and reference electrode 40 is substantially de-coupled from the electric field generated between the discharge electrode 70 and reference electrode 40 . Thus, changes in the relative position of the spray nozzle 20 with respect to reference electrode 40 or changes in the electric field strength generated between the spray nozzle 20 and reference electrode 40 have little, if any, impact on the electric field generated between the discharge electrode 70 and the reference electrode 40 . Similarly, changes in the relative position of the discharge electrode 70 with respect to reference electrode 40 or changes in the electric field strength generated between the discharge electrode 70 and reference electrode 40 have little, if any, impact on the electric field generated between the spray nozzle 20 and the reference electrode 40 .
However, the existence and the position of the reference electrode contribute with the discharge electrode to controlling the direction of the aerosol delivery. Without the reference electrode, the charged aerosol would tend to be attracted toward the tip of the discharge electrode. The positive ions from the tip of the discharge electrode would also be attracted toward the aerosol and the spray nozzle and the spray nozzle tip. The aerosol and the positive ions would then tend to meet substantially in between the spray nozzle and the discharge electrode. The reference electrode is positioned such that it reduces this tendency so that the aerosol and the positive ions intersect more near the intersection of their respective central axes downstream of the electrodes. In FIG. 1, the discharge electrode is positioned such that the aerosol is moved generally in the direction of the positive ion flow and toward the exit mouthpiece 8 and the user.
The discharge electrode 20 and the reference electrode 40 are fixed in the EHD device in such a manner and with respect to the spray nozzle 20 such that a gas flow path (such as at 18 and/or 28 ) is provided alongside the spray nozzle. For example, in FIG. 1, the electrodes are fastened such that air may enter the EHD device through the mouthpiece 8 in the housing 12 and move along the inside of the housing wall at 16 and then along the gas flow path at 18 and/or 28 . When used to deliver therapeutic agents by inhalation, the user's mouth would typically cover the mouthpiece so that additional openings 13 may be necessary in the housing 12 to allow entry of gas or air. The position of the openings 13 may be moved to allow more or less gas to move along the gas flow paths 18 and 28 . This air movement along the gas flow path 18 and/or 28 has been found to contribute to a very stable Taylor cone at the tip 22 . The airflow also helps move the aerosol to the location where the positive ions from the discharge electrode impact the aerosol. The airflow along the path 18 and/or 28 appears to be at least partially induced by the corona wind from discharge electrode 70 .
Preferably, reference electrode 40 and spray nozzle 20 are positioned such that the electric field intensity is largest between spray tip 22 and spray end 42 , as for example when they are angled toward each other and the spray tip 22 and the spray end 42 are relatively closer together than other parts of the electrodes. This relative position of spray nozzle 20 and reference electrode 40 minimizes any tendency for the dispensed fluid to coat or collect on the outside of spray nozzle 20 . It also has some positive effect on the induced air flow past at 18 and/or 28 due to the corona wind. Collection of fluid on the outside of spray nozzle 20 (with the spray nozzle fairly vertical and the nozzle tip at substantially the lowest point) is most likely when the spray nozzle 20 dispenses the aerosol in the upward direction and is least likely when the spray nozzle 20 dispenses the aerosol in the downward direction. Collection of fluid reduces the quantity of the fluid that is converted into an aerosol. Additionally, this fluid collection has the potential to disrupt or interfere with the Taylor cone. Any disruption or interference with this cone affects the aerosol droplet size and the droplet size distribution. This relative position of spray nozzle 20 and reference electrode 40 also minimizes the tendency for the aerosol to coat or collect on the reference electrode 40 . Any collection of the aerosol on the reference electrode 40 reduces the quantity of aerosol delivered to the user from the EHD aerosol sprayer 10 .
For the above mentioned reasons it is desirable to orient the spray nozzle more in a vertical orientation (generally above the horizontal) so that the fluid is restrained by gravity from wicking up the nozzle and the aerosol generally moves downward away from the tip. This also suggests that the movement of the corona wind is most beneficially away from the nozzle tip 22 such as when the central axis 74 of the discharge electrode is oriented parallel to the central axis 24 of the nozzle or at some acute angle. Of course, the corona wind must intercept the aerosol in some manner to affect the direction of the aerosol.
When used to deliver therapeutic agents by inhalation, it is also desirable to deliver an aerosol horizontally to the user's mouth. This desire suggests that it would be more beneficial to shift the direction of the aerosol by up to 90 degrees so that it is delivered substantially horizontally to the user. Both of these desires may be accomplished by maintaining an angle 30 between the nozzle central axis 24 and the discharge electrode central axis 74 between about 0 and 120 degrees. The invention will continue to work at angles in excess of 120 degrees, but it will be understood that the aerosol will be redirected by the corona wind more in the general direction of the nozzle at these higher angles. Ultimately, at 180 degrees, the corona wind would be moving substantially parallel to the nozzle central axis and may substantially defeat the purpose of the invention as described earlier. The aerosol is most preferably directed by the discharge electrode toward the mouthpiece 8 and ultimately to the user contacting the mouthpiece. It may be useful when the angle 30 is a large number to use more than one reference electrode 40 between the spray nozzle and the discharge electrode.
Also, the best results in inducing airflow past the Taylor cone have been observed when the discharge electrode is oriented so that the corona wind moves in a direction substantially away from the spray nozzle. This may be accomplished by maintaining an angle 30 between the nozzle central axis 24 and the discharge electrode central axis 74 between about 0 and 90 degrees, preferably between 0 and 60 degrees.
The discharge electrode tip 72 may be located either upstream or downstream of the spray tip 22 . As mentioned earlier, in this upstream or downstream position proximate spray tip 22 , the ions from the discharge electrode may intercept the aerosol a short distance downstream of the spray tip 22 before the aerosol has dispersed to any great degree. Preferably, the discharge electrode is positioned proximate the spray nozzle such that the ion cloud intercepts the aerosol at a distance of less than about 4 centimeters and more preferably less than 2 centimeters from the spray nozzle tip before the aerosol cloud has had a chance to disperse to a large degree. By the term “upstream” of the spray tip 22 , we mean that when the spray nozzle is in a vertical orientation, the discharge electrode tip is above a plane through the spray tip 22 perpendicular to the nozzle central axis 24 . By the term “downstream” we mean that the discharge electrode tip would be below the perpendicular line under the above conditions. Whether the discharge electrode is positioned upstream or downstream of the spray nozzle, the discharge electrode should be located outside of the spray path of the aerosol. As mentioned, this spray path tends to enlarge greatly as the aerosol disperses downstream of the spray nozzle.
Preferably, reference electrode 40 and discharge electrode 70 are positioned such that the electric field intensity is largest between spray end 42 and discharge tip 72 . This relative position of discharge electrode 70 and reference electrode 40 minimizes the quantity of ionized air molecules that flow to the ground electrode 40 . Thus, this configuration maximizes the number of ionized air molecules (corona wind) available to discharge the aerosol. Additionally, this configuration also tends to maximize the aerosol quantity that moves with the corona wind and the induced air flow past the Taylor cone.
DC voltage source 30 electrically connects spray nozzle 20 to reference electrode 40 and maintains spray nozzle 20 at a negative potential. DC voltage source 60 electrically connects discharge electrode 70 to reference electrode 40 and maintains discharge electrode 70 at a positive potential. A positive potential is preferred on the discharge electrode 70 to form the corona wind discussed above. A negative voltage on the discharge electrode 70 would more readily form an ion stream. However, these negative ions (electrons) have a higher mobility (velocity) than air molecules, but they also have a very small mass. Thus, electrons have far less momentum than air molecules so that using electrons to discharge the aerosol would have relatively little impact on the movement of the aerosol but in some applications may be useful.
The positive voltage on the discharge electrode 70 strips an electron from an air molecule leaving the air molecule with a positive charge. Consequently, the ionized air molecule will move by repulsion away from the discharge electrode 70 . Additionally, the ionized air molecules are attracted to the negative charge on the aerosol. In the embodiments where the reference electrode 40 does not cross line LOS, the ionized air molecule will also be attracted to the negative voltage on the spray nozzle 20 . Due to the aerosol's closer proximity most, if not all, of the ionized air interacts with the aerosol. Thus, the predominate motion direction of the ionized air molecules is determined by the orientation of the ionization sites on the discharge electrode, which is typically directly away from the discharge electrode 70 and generally parallel to the central axis 74 . Consequently, the aerosol also moves in the same direction as determined by the characteristics and/or position/orientation of the discharge electrode 70 .
Voltage sources 30 and 60 typically provide between one and twenty kilovolts, with the preferred voltage being between three and six kilovolts. The best voltage for aerosolizing a particular fluid depends on the fluid's properties, principally the conductivity/resistivity, viscosity, surface tension, and flow rate. Additionally, the relative positions of the spray nozzle 20 , reference electrode 40 , and discharge electrode 70 will typically have some influence on the best voltage(s) to be applied to the spray nozzle 20 and discharge electrode 70 . Furthermore, the type of nozzle tip 22 and the aerosol droplet size will also influence the ideal voltage utilized in a particular application. To some extent, the magnitude of the voltage may be used to control the velocity of the ions from the discharge electrode. The person of ordinary skill in the art of designing and using EHD sprayers is familiar with typical voltages utilized for specific fluids and equipment geometry.
In some embodiments, the addition of a resistance in series with the voltage sources 30 and/or 60 may be required to prevent arcing between the spray nozzle 20 and reference electrode 40 , or between reference electrode 40 and discharge electrode 70 . The resistance is intended to limit current so that arcing is either minimized or cannot be maintained. To be effective without overly limiting the current to the electrodes, the resistance should have a value of hundreds of kilohms to hundreds of megohms. In a preferred embodiment and operating at preferred voltages, the resistance has a value between about ten and twenty megohms.
Ground 50 maintains the reference electrode 40 at a reference voltage. Preferably, this reference voltage is approximately zero volts. Preferably, the reference electrode is electrically paired with the nozzle and the discharge electrode. However, in some applications, the “reference electrode” is not an electrode at all and may instead be made of a dielectric material. This may promote wetting of the dielectric “reference electrode” by charged aerosol; however, if the application is one that only requires a short burst of aerosol (perhaps several seconds), then this dielectric “reference electrode” may still function.
FIG. 2 illustrates a second EHD sprayer 200 configured to control the aerosol discharge direction. Sprayer 200 employs a spray nozzle 220 that is electrically connected to a reference electrode 240 with a voltage source 230 . Discharge electrode 224 is connected to reference electrode 240 with a voltage source 260 . The spray nozzle 220 and the discharge electrode 224 are similar to spray nozzle 20 and the discharge electrode 70 discussed above. Voltage sources 230 and 260 are also similar to voltage sources 30 or 60 described above. Ground 250 provides the same function and reference voltage to that disclosed above for ground 50 . The reference electrode 240 has been modified so that the electric field produced between spray nozzle 220 and reference electrode 240 is symmetric around the outside surface of spray nozzle 220 . An airflow path at 218 is created by the reference electrode 240 (which is open to intake airflow at the upstream end nearest the voltage supply and opposite the spray tip 222 ) and the spray nozzle 220 . Air may move up the housing walls 212 at 216 and thence down the flow path 218 past the Taylor cone. When used to deliver therapeutic agents by inhalation, the user's mouth would typically cover the mouthpiece so that additional openings (similar to the openings 13 in FIG. 1) may be necessary in the housing 212 to allow entry of gas or air.
Preferably, reference electrode 240 , the spray nozzle 220 and the discharge tip 226 are positioned such that the electric field intensity is largest between spray tip 222 and spray end 242 and between the spray end 242 and the discharge tip 226 . This relative position of spray nozzle 220 and ground electrode 240 minimizes any tendency for the fluid dispensed to coat or collect on the outside of spray nozzle 220 . The fluid collection on the outside of spray nozzle 220 is most likely when the spray nozzle 220 dispenses the aerosol in the upward direction, and is least likely when the spray nozzle 220 dispenses the aerosol in the downward direction. The collection of fluid reduces the quantity of the fluid that is converted into an aerosol. Additionally, this fluid collection has the potential to disrupt or interfere with the Taylor cone. Any disruption or interference with this cone affects the aerosol droplet size and the droplet size distribution.
The positioning of the spray tip 222 with respect to spray end 242 of the reference electrode 240 is fairly important in minimizing the tendency for the aerosol to coat or collect on the ground electrode 240 . A preferred position of the reference electrode would be such that the spray end is approximately on the line of sight between the spray nozzle tip 222 and the discharge tip 226 . Positioning the reference electrode a short distance from this line of sight is still useful and part of the invention; however, as the position of the reference electrode is changed (back toward the voltage source in FIG. 2) to expose more of the spray nozzle, the aerosol tends to move toward the discharge electrode and to neutralize and coat the discharge electrode more. If the position of the reference electrode is changed to more cross over the line of sight (that is, to more surround the spray nozzle tip and shield it from the discharge electrode) the tendency is for the aerosol to coat the inside of the reference electrode.
The preferred shape for spray nozzle 220 is a cylindrical tube. Consequently, the preferred shape for the reference electrode 240 is a truncated cone with the smaller diameter opening forming spray end 242 . This configuration of sprayer 200 provides an approximately conical electrical field between spray tip 222 and spray end 242 . Other sprayer 200 geometry could also generate symmetric diverging electric fields. These electric fields cause the aerosol to move away from sprayer 200 , with the motion direction aligned generally with the longitudinal axis of spray nozzle 220 .
FIG. 3 illustrates a third EHD sprayer 300 configured to control the aerosol discharge direction and stabilize the Taylor cone. Sprayer 300 employs a spray nozzle 320 that is electrically connected to a first reference electrode 340 with a voltage source (not shown) to provide a negative charge on the spray nozzle with respect to the first reference electrode 340 . Discharge electrode 370 is connected to a voltage source (not shown) which places a positive charge on the discharge electrode with respect to the first reference electrode 340 . The spray nozzle 320 and the discharge electrode 370 are similar to spray nozzle 20 and the discharge electrode 70 discussed above. The voltage sources are also similar to voltage sources 30 or 60 described above. Positive ions are created at the tip 372 of the discharge electrode and a corona wind is created in a direction substantially along the axis 374 toward the mouthpiece 308 of the device.
The embodiment of FIG. 3 also incorporates a second reference electrode 342 near the discharge electrode on the side opposite the first reference electrode 340 and a third reference electrode 344 near the spray nozzle on the side opposite the first reference electrode. Reference electrodes 340 , 344 and spray nozzle 320 create an air flow path at 318 and 328 respectively. Air is induced at least partially by the corona discharge to move down the flow path 318 and 328 past the Taylor cone to provide stability. Furthermore, reference electrodes 340 , 344 and spray nozzle 320 provide greater symmetry in the electric field or spray tip 342 than what can be achieved in spray nozzle 20 . Likewise, reference electrodes 340 , 342 and discharge electrode 370 provide symmetry in the electric field at discharge tip 372 so that positive ions are more likely to move along axis 374 than in the sprayer shown in FIG. 1 .
The EHD sprayers shown in FIGS. 1-3 may be arranged into an EHD sprayer employing multiple spray nozzles. Utilizing multiple spray nozzles permits an EHD sprayer to aerosolize greater volumes of fluid required in many aerosol sprayer applications. These spray nozzles may be arranged in any shape or array desired as long as the electric field interactions are taken in to account. The nozzles may be arranged in circles, lines, multiple stacked lines or random stacks may be used, for example.
An exemplary multiple nozzle configuration is illustrated in FIGS. 4-6. These figures illustrate a linear spray nozzle array in a device for pulmonary delivery of drugs in a clinical setting where the source of fluid to be aerosolized is remote from the EHD sprayer. An EHD sprayer is housed in a device 100 remote from the source of fluid. The EHD sprayer 100 shown in FIGS. 4-6 includes a housing 110 , air inlet 112 , spray nozzles 120 , reference electrodes 140 , discharge electrodes 170 , spray electrodes 180 , and manifold 190 . A DC voltage source (see FIG. 1) electrically connects and maintains the spray nozzles 120 at a negative voltage with respect to reference electrodes 140 . A second DC voltage source (see FIG. 1) electrically connects and maintains the discharge electrodes 170 at a positive voltage with respect to reference electrodes 140 . Ground (see FIG. 1) maintains reference electrodes 140 at a ground reference voltage (approximately zero volts DC). The housing 110 contains and supports the spray nozzles 120 , ground electrodes 140 , discharge electrodes 170 , spray electrodes 180 , and manifold 190 . All of these elements are supported by the housing 110 so that air can enter the housing such as at 114 and through holes in perforated plate 118 so as to be available above the reference electrodes 140 to be induced by the corona wind along the gas flow path 116 past the spray nozzles 120 and past the Taylor cones produced at the tip 122 of the spray nozzles. Additionally, housing 110 may contain the voltage source(s) or provide connections for external voltage source(s).
Each spray nozzle 120 is typically a capillary tube or other tube, electrode or other shape used to deliver fluid in EHD applications. In some embodiments the tube used for a spray nozzle 120 may have a spray tip 122 designed specifically for EHD spray applications. This tip promotes the Taylor cone formation. Additionally, this tip may stabilize the Taylor cone, which consequently tends to reduce the deviation in the droplet size in the resulting aerosol. The induced airflow along the gas flow path 116 additionally stabilizes the Taylor cone.
Each discharge electrode 170 typically has a knife edge or needle like discharge tip 172 . These tip shapes tend to promote the formation of ionized air molecules. Alternatively, any tip shape that is capable of ionizing air molecules may be utilized.
In many uses it is desirable to maintain an angle between the spray nozzle and the discharge electrodes between about 0 and 120 degrees. The invention will continue to work at angles in excess of 120 degrees, but it will be understood that the aerosol will be redirected by the corona wind more in the general direction of the nozzle at these higher angles. Ultimately, at 180 degrees, the corona wind would be moving substantially parallel to the nozzle central axis and would potentially move the aerosol back to the nozzle. This would substantially defeat the purpose of the invention. When using multiple spray nozzles and discharge electrodes, it is useful to maintain substantially the same angle between all the spray nozzles and all the discharge electrodes; however, it is sufficient to maintain that angle between any of them such that the overall effect of the corona wind is to move the aerosol away from the spray nozzles toward the desired target/user and/or to induce the flow of air along the gas flow path 116 past the Taylor cone. The spray nozzles and discharge electrodes need not be paired in any one to one relationship.
Also, the best results in inducing airflow past the Taylor cone have been observed when the discharge electrodes are oriented so that the corona wind moves in a direction substantially away from the spray nozzle. This may be accomplished by maintaining an angle between a plane cutting through the nozzles and a plane cutting through the discharge electrodes between about 0 and 90 degrees, preferably between 0 and 60 degrees. And the discharge electrode tips 172 may be located either upstream or downstream of the spray tips 122 . As mentioned earlier, in this position upstream or downstream proximate the spray tips 122 , the ions from the discharge electrode may intercept the aerosol a short distance from the spray tips 122 before the aerosol has dispersed to any great degree. By the term “upstream” of the spray tips 122 , we mean that when the spray nozzles are in a vertical orientation, the discharge electrode tips are above a line drawn through the spray tips 122 perpendicular to a central axis of the spray nozzles. By the term “downstream” we mean that the discharge electrode tips would be below the perpendicular line under the above conditions.
In the embodiment shown, there are three reference electrodes 140 a , 140 b , and 140 c . Other embodiments may use different configurations of reference electrodes 140 as required to develop and shape the electric fields desired for a particular application. Reference electrode 140 a is located above spray nozzles 120 .
Preferably, reference electrodes 140 a and 140 b and spray nozzles 120 are positioned such that the electric field intensity is largest between spray tips 122 and spray ends 142 a and 142 b . This relative position of spray nozzles 120 and reference electrodes 140 a and 140 b minimizes any tendency for the fluid to coat or collect on the outside of spray nozzles 120 . The collection of fluid on the outside of spray nozzles 120 is most likely when the spray nozzles 120 dispense aerosol in the upward direction, and is least likely when the spray nozzles 120 dispense aerosol in the downward direction. The collection of fluid reduces the quantity of the fluid that is converted into an aerosol. Additionally, this fluid collection has the potential to disrupt or interfere with the Taylor cone. Any disruption or interference with this cone affects the aerosol droplet size and the droplet size distribution. This relative position of spray nozzles 120 and reference electrodes 140 a and 140 b also minimizes the tendency for the aerosol discharged to coat or collect on the reference electrodes 140 a and 140 b . Any collection of the aerosol on the reference electrodes 140 a and 140 b reduces the quantity of aerosol discharged from the EHD aerosol sprayer 100 .
Reference electrode 140 b is also located between spray nozzles 120 and discharge electrodes 170 . In some embodiments, the spray end 142 b of reference electrode 140 b may be located to intersect the line LOS (see FIG. 1) that connects a spray tip 122 to a discharge tip 172 . In the preferred embodiment, however, the reference electrode 140 b is positioned so that reference electrode 140 b crosses line LOS (see FIG. 1 ). With the reference electrode in the preferred position, the electric field generated between the spray nozzles 120 and reference electrode 140 b is substantially de-coupled from the electric field generated between the discharge electrodes 170 and reference electrode 140 b . Thus, changes in the relative position of the spray nozzles 120 with respect to reference electrode 140 b , or changes in the electric field strength generated between the spray nozzles 120 and reference electrode 140 b have minimal impact on the electric field generated between the discharge electrodes 170 and the reference electrode 140 b . Similarly, changes in the relative position of the discharge electrodes 170 with respect to reference electrode 140 b , or changes in the electric field strength generated between the discharge electrodes 170 and reference electrode 140 b have minimal impact on the electric field generated between the spray nozzles 120 and the reference electrode 140 b.
Preferably, reference electrodes 140 b and 140 c and discharge electrodes 170 are positioned such that the electric field intensity is largest between spray ends 142 b and 142 c and discharge tips 172 . This relative position of discharge electrodes 170 and reference electrodes 140 b and 140 c minimizes the quantity of ionized air molecules that flow to the reference electrodes 140 b and 140 c .Thus, this configuration maximizes the number of ionized air molecules (corona wind) available to discharge the aerosol. Additionally, this configuration also tends to maximize the aerosol quantity that moves with the corona wind. Preferably, reference electrodes 140 b and 140 c are also positioned symmetrically to discharge electrodes 170 . This geometric symmetry promotes symmetry in the electric field at discharge tips 172 which tends to promote ionized air flow across the plane intersecting the discharge electrodes.
A DC voltage source (see FIG. 1) electrically connects spray nozzles 120 to reference electrodes 140 a and 140 b and maintains spray nozzles 120 at a negative potential. A second DC voltage source (see FIG. 1) electrically connects discharge electrodes 170 to reference electrodes 140 b and 140 c and maintains discharge electrodes 170 at a positive potential.
A positive potential is preferred on the discharge electrodes 170 to form the corona wind discussed above. A negative voltage on the discharge electrodes 170 would form an ion stream easier; however, as described above these negative ions (electrons) have a very low momentum. Thus, using electrons to discharge the aerosol has relatively little impact on the movement of the aerosol as compared with the effect of positive ions. However, as stated above, in some applications it may actually be useful to have a negative charge on the discharge electrode, though it is not preferred in the drug delivery application.
The positive voltage on the discharge electrodes 170 strips an electron from an air molecule leaving the air molecule with a positive charge. Subsequently, the ionized air molecule will move away from the discharge electrodes 170 . Additionally, the ionized air molecules are attracted to the negative charge on the aerosol. In the embodiments where the reference electrode 140 b does not cross line LOS (see FIG. 1 ), the ionized air molecule will also be attracted to the negative voltage on the spray nozzles 120 . Due to the closer proximity of the aerosol most, if not all, of the ionized air interacts with the aerosol. The addition of lower reference electrode 140 c and the resulting impact on the electric field or discharge tips 172 provide a symmetry to the ionizing field. Thus, the predominate motion direction of the ionized air molecules is directly away from the discharge electrodes 170 and along the direction that the discharge electrodes 170 are pointing. Consequently, the aerosol also moves in the direction that the discharge electrode is pointing. Preferably, this direction is generally toward the device exit which, in the drug delivery application is toward the mouth of the user. In any event, the motion direction of the aerosol is principally controlled by the position/orientation of the discharge electrodes 170 .
In some applications, it may be useful to begin the corona discharge and the corona wind just prior to production of aerosol. This may assist in more completely moving the aerosol droplets away from the spray nozzle. Typically, when the voltage to the discharge electrode and the spray nozzle are applied at the same time, the positive corona begins prior to the aerosolization of the fluid because the electron stripping process is more rapid than the EHD droplet formation process. However, at times, it is useful to apply the voltage to the discharge electrode just prior to applying the voltage to the spray nozzle.
When the spray nozzles are arranged in an array, it may be necessary to add spray electrodes to the array to balance and/or shape the electric fields experienced by the other spray nozzles. A spray electrode may be a spray nozzle that is plugged, blocked, or not provided with fluid. Alternatively, the spray electrode may be shaped similarly to a discharge electrode. Additionally, spray nozzle spacing may serve a similar function.
When using a linear array as shown in FIGS. 4-6 for sprayer 100 , spray electrodes 180 are placed at each end of the linear array. These spray electrodes 180 tend to balance and/or even out the electric field without having to adjust the voltages on individual spray nozzles 120 , so that the adjacent spray nozzle 124 is subject to a similar electric field as the other spray nozzles 120 . With each spray nozzle 120 subject to similar electric fields, each Taylor cone will then behave in a predictable manner. Consequently, the aerosol droplet size and size distribution can be predicted and controlled.
Spray nozzles 120 may be joined to manifold 190 that is supported by housing 110 . Manifold 190 , if employed, provides a fluid connection between a fluid source (not shown) and each spray nozzle 120 . Additionally, manifold 190 interconnects each spray nozzle 120 . Thus, each spray nozzle should experience approximately the same fluid pressure and each spray nozzle should experience similar fluid flow rates. Similar fluid flow rates also promote similar Taylor cone behavior. Consequently, the aerosol droplet size and size distribution can be predicted and controlled.
Manifold 190 , if manufactured from a conducting material, can also electrically connect the voltage source to each spray nozzle 120 and to each spray electrode 180 installed. Due to the relatively large size of manifold 190 as compared to a spray nozzle 120 onto spray electrode 180 , the voltage provided to each spray nozzle 120 or each spray electrode 180 should be similar. Consequently, the Taylor cone behavior can be predicted with greater certainty.
We have disclosed the preferred EHD apparatus and method in detail. As described earlier, the invention is also useful for delivery of many other aerosol products (e.g. fragrances, lubricants, etc). In these other uses it may be useful to move an uncharged aerosol. In this case, the discharge electrode described herein may more accurately be termed an “ionization electrode” because the ions do not discharge the charge on the aerosol, but merely provide the momentum to the corona wind to direct the flow in the desired direction. This corona wind could either be a positive or negative ion stream. Apparatus according to the invention would include aerosol source, an ionization electrode for developing the corona wind along a desired path, a reference electrode and a voltage source.
In summary, numerous benefits have been described which result from employing the concepts of the invention. The foregoing description of the invention's preferred embodiment has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. These embodiments were chosen and described to best illustrate the principles of the invention and its practical application, to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications, as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto. | The invention provides an aerosol delivery method and system for producing a charged electrohydrodynamic (EHD) aerosol, discharging the aerosol and moving the discharged aerosol in a desired direction without substantial wetting of the device. The delivery system may include a spray nozzle for dispensing the fluid to be aerosolized and negatively charging the aerosol droplets, a discharge electrode generally downstream of the spray nozzle for generating a positive ion stream which intercepts and electrically neutralizes the negative aerosol droplets while also imparting a desired movement on the aerosol in a direction generally away from the discharge electrode and a reference electrode between the spray nozzle and the discharge electrode for modifying the electric field between the spray nozzle and the discharge electrode. | 1 |
TECHNICAL FIELD
The present invention relates to generally to textile dyeing and more particularly to the introduction of dyes and other chemicals into a process for dyeing a textile material in a supercritical fluid.
BACKGROUND ART
It will be appreciated by those having ordinary skill in the art that conventional aqueous dyeing processes for textile materials, particularly hydrophobic textile materials, generally provide for effective dyeing, but possess many economic and environmental drawbacks. Particularly, aqueous dyebaths that include organic dyes and co-solvents must be disposed of according to arduous environmental standards. Additionally, heat must be applied to the process to dry the textile material after dyeing in an aqueous bath. Compliance with environmental regulations and process heating requirements thus drive up the costs of aqueous textile dyeing to both industry and the consuming public alike. Accordingly, there is a substantial need in the art for an alternative dyeing process wherein such problems are avoided.
One alternative to aqueous dyeing that has been proposed in the art is the dyeing of textile materials, including hydrophobic textile materials like polyester, in a supercritical fluid. Particularly, textile dyeing methods using supercritical fluid carbon dioxide (SCF-CO 2 ) have been explored.
However, those in the art who have attempted to dye textile materials, including hydrophobic textile materials, in SCF-CO 2 have encountered a variety of problems. These problems include, but are not limited to, “crocking” (i.e. tendency of the dye to smudge when the dyed article is touched) of the dye on the dyed textile article; unwanted deposition of the dye onto the article and/or onto the dyeing apparatus during process termination; difficulty in characterizing solubility of the dyes in SCF-CO 2 ; difficulty introducing the dyes into the SCF-CO 2 flow; and difficulty in preparing the dyes for introduction into the dyeing process. These problems are exacerbated when attempts to extrapolate from a laboratory process to a plant-suitable process are made.
PCT Publication No. WO 97/13915, published Apr. 17, 1997, designating Eggers et al. as inventors (assigned to Amman and Söhne GmbH and Co.) discloses a system for introducing dye into a CO 2 dyeing process which comprises a bypass flow system associated with the main circulation system that includes a color preparing vessel. The bypass is opened, after a certain temperature and pressure are reached, so that SCF-CO 2 flows through the color preparing vessel and dissolves the previously loaded dye(s). The SCF-CO 2 -containing dissolved dye flows from the bypass back into the main circulation system where it joins the bulk of the SCF-CO 2 flow that is used to accomplish dyeing.
PCT Publication No. WO 97/14843, published Apr. 24, 1997, designating Eggers et al. as inventors (assigned to Amman and Söhne GmbH and Co.) discloses a method for dyeing a textile substrate in at least one supercritical fluid, wherein the textile substrate is preferably a bobbin and the fluid is preferably SCF-CO 2 . The disclosed invention attempts to prevent color spots from forming on the textile substrate during dyeing and is directed to ways of incorporating the dye material into the supercritical fluid using the basic bypass system as described above in PCT WO 97/13915.
The method involves the use of at least one dye which is contacted with the supercritical fluid as a dye bed, dye melt, dye solution, and/or dye dispersion before and/or during actual dyeing in an attempt to form a stable solution of dye in the supercritical fluid. A stated goal is avoiding the formation of dye agglomerates having a particle size of more than 30 microns, preferably more than 15 microns, in the solution.
This invention attempts to accomplish these aims through a variety of embodiments. In one embodiment, the dye bed is provided with inert particles, in particularly glass and/or steel balls, to prevent agglomeration. Alternatively, the dye bed itself can consist of inert particles coated with the dye. SCF-CO 2 is then passed through the dye bed to incorporate the dye within the SCF-CO 2 .
However, there are a number of significant drawbacks to this embodiment of the dye introduction method disclosed by Eggers et al. PCT Publication No. WO 97/14843. For example, use of a fixed or fluidized bed to introduce dye into the dyeing system can be hindered if appropriate flow conditions are not present. The dye particles must be at all times in intimate and vigorous contact with the supercritical fluid for effective dissolution. If this is not the case, the dissolution rate will be low and will likely not be complete by the end of the dyeing cycle.
Moreover, promotion of a high convective mass transfer coefficient (i.e., intimate and vigorous mixing) can result in substantial pressure losses through the dye-add vessel. Because of their relatively low viscosity values, supercritical fluids are easily diverted to areas of lower resistance, which can lead to mechanical problems such as channeling and stagnation. Channeling refers to the development of a fluid path, or channel, through a particulate bed that circumvents uniform flow throughout the bed; i.e., a stream of fluid develops through the bed such that the flow in the region where the stream exists is greater than the flow of fluid in the rest of the bed. In this case, the particles not in the channel are not properly contacted by the fluid. These conditions, in turn, result in dye particles not being contacted in a manner that will allow substantially complete dissolution.
Insuring the proper flow conditions when using fluidized dye beds, fixed dye beds, or dye bed holding devices requires very careful and complex design of the internals of the dye-add vessel in order to assure good mixing and to avoid mechanical flow problems without excessive pressure drop. Indeed, it is likely that dye bed holding devices that are chambered to force uniform flow of fluid through the bed, such as those proposed for use in dye introduction by Eggers et al., PCT Publication No. WO 97/14843, also suffer very high pressure losses.
Another drawback arises when the fluidized and fixed dye bed is installed in the system in a bypass loop. Since the dye dissolution process is rate limiting, this arrangement couples the dyeing process to the dye dissolution process, which is generally undesirable. In contrast, the dye should be introduced at a rate consistent with dyeing the textile material as rapidly as possible but also in a level manner.
An alternative embodiment of the dye injection method disclosed by Eggers et al. PCT Publication No. WO 97/14843 involves injection of the dye as a melt incorporated in an inert gas, preferably nitrogen or carbon dioxide (with property of being inert for these two gases being a function of the process conditions). It has been observed by the present applicants that melting of disperse dyes can lead to decreased solubility in SCF-CO 2 . This circumstance indicates that the applicability of this embodiment of the disclosed dye injection method is limited.
Yet another embodiment of the dye introduction method disclosed by Eggers et al. PCT Publication NO. WO 97/14843 involves delivery of the dye into the supercritical fluid flow as a solution or suspension. When a solution is being injected and water-soluble dyes are being used, the recommended injection solvent is water. For water-insoluble dyes, a variety of common nontoxic injection solvents are suggested, with acetone, which readily dissolves disperse dyes, being foremost. The water-insoluble dyes are injected as a solution or suspension in the chosen solvent. In the case that a suitable nontoxic solvent cannot be found or the required amount of solvent is so great that it adversely affects the dyeing process, injection of a dispersion, preferably an aqueous dispersion, is recommended.
This embodiment of the method disclosed by Eggers et al. PCT Publication No. WO 97/14843 also suffers from several drawbacks. Firstly, water is an anti-solvent in SCF-CO 2 when used with disperse dyes. Thus, for SCF-CO 2 , the presence of water results in a significantly impaired dyeing process to the extent that it is questionable whether dyeing could be accomplished at all. At best, the action of water in the SCF-CO 2 would cause the dye to reside in the dyeing process as dispersion. In the worst case, the dye would exist as an unstable suspension with unsuitable properties for dyeing. Secondly, in the case that a suitable SCF-CO 2 /water/dye dispersion was obtained, the SCF-CO 2 dyeing process would be similar to the conventional aqueous process, the replacement of which is a desired goal in the art.
Poulakis et al., Chemiefasern/Textilindustrie , Vol. 43-93, February 1991, pages 142-147 discuss the phase dynamics of supercritical carbon dioxide. An experimental section describing an apparatus and method for dyeing polyester in supercritical carbon dioxide in a laboratory setting is also presented. Thus, this reference only generally describes the dyeing of polyester with supercritical carbon dioxide in the laboratory setting and is therefore believed to be limited in practical application.
U.S. Pat. No. 5,199,956 issued to Schienker et al. on Apr. 6, 1993 describes a process for dyeing hydrophobic textile material with disperse dyes by heating the disperse dyes and textile material in SCF-CO 2 with an azo dye having a variety of chemical structures. The patent thus attempts to provide an improved SCF-CO 2 dyeing process by providing a variety of dyes for use in such a process.
U.S. Pat. No. 5,250,078 issued to Saus et al. on Oct. 5, 1993 describes a process for dyeing hydrophobic textile material with disperse dyes by heating the disperse dyes and textile material in SCF-CO 2 under a pressure of 73 to 400 bar at a temperature in the range from 80° C. to 300° C. Then the pressure and temperature are lowered to below the critical pressure and the critical temperature, wherein the pressure reduction is carried out in a plurality of steps.
U.S. Pat. No. 5,578,088 issued to Schrell et al. on Nov. 26, 1996 describes a process for dyeing cellulose fibers or a mixture of cellulose and polyester fibers, wherein the fiber material is first modified by reacting the fibers with one or more compounds containing amino groups, with a fiber-reactive disperse dyestuff in SCF-CO 2 at a temperature of 70-210° C. and a CO 2 pressure of 30-400 bar. Specific examples of the compounds containing amino groups are also disclosed. Thus, this patent attempts to provide level and deep dyeings by chemically altering the fibers prior to dyeing in SCF-CO 2 .
U.S. Pat. No. 5,298,032 issued to Schlenker et al. on Mar. 29, 1994 describes a process for dyeing cellulosic textile material, wherein the textile material is pretreated with an auxiliary that promotes dye uptake subsequent to dyeing, under pressure and at a temperature of at least 90° C. with a disperse dye from SCF-CO 2 . The auxiliary is described as being preferably polyethylene glycol. Thus, this patent attempts to provide improved SCF-CO 2 dyeing by pretreating the material to be dyed.
Despite extensive research into SCF-CO 2 textile dyeing processes, there has been no disclosure of a suitable method for introducing dyes or other textile treatment materials into such processes. An environmentally and economically sound method for introducing dyes or other textile treatment materials would be particularly desirable in the plant-scale application of a SCF-CO 2 textile dyeing process. Therefore, the development of such a method meets a long-felt and significant need in the art.
DISCLOSURE OF THE INVENTION
A process for introducing a textile treatment material into a textile treatment system is disclosed. The process comprises: (a) providing a preparation vessel in fluid communication with a textile treatment system; (b) loading a textile treatment material into the preparation vessel; (c) dissolving or suspending the textile treatment material in near-critical liquid carbon dioxide or supercritical fluid carbon dioxide in the preparation vessel; and (d) introducing the dissolved or suspended textile treatment material into a textile treatment system. A system suitable for use in carrying out the process is also disclosed.
The process and system of the present invention are preferred for use with a textile treatment system that utilizes SCF-CO 2 as a treatment medium. Optionally, the textile treatment material can be selected from a group including, but not limited to, a brightening agent, a whitening agent, a dye and combinations thereof.
Accordingly, it is an object of the present invention to provide an improved process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF-CO 2 textile treatment system.
It is another object of the present invention to provide an environmentally benign process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF-CO 2 textile treatment system.
It is another object of the present invention to provide a process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF-CO 2 textile treatment system, that reduces the loss of such textile treatment materials in a textile processing operation.
It is yet another object of the present invention to provide a process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF-CO 2 textile treatment system, that can be isolated from the textile treatment system to thereby facilitate addition of dyes and other textile treatment materials thereto.
It is a further object of the present invention to provide an improved process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF-CO 2 textile treatment system, in accordance with an introduction profile that facilitates correspondence between the introduction rate and an appropriate dyeing rate.
It is a further object of the present invention to provide an improved process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF-CO 2 textile treatment system, at an introduction point where there is high fluid shear to ensure proper mixing of the introduced treatment material into the textile treatment system.
It is yet a further object of the present invention to provide an improved process and system for introducing dyes or other textile treatment materials into a textile treatment system, preferably a SCF-CO 2 textile treatment system, that utilizes supercritical fluid and/or near-critical liquid carbon dioxide as a solvent for the dye or other textile treatment material.
Some of the objects of the invention having been stated herein above, other objects will become evident as the description proceeds, when taken in connection with the accompanying drawings as best described herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a prior art system for introducing textile treatment materials into a SCF-CO 2 textile dyeing process;
FIG. 2 is a schematic of a system for introducing textile treatment materials into a textile treatment system wherein the system utilizes a stirred dye-add vessel in accordance with a process of the present invention;
FIG. 3 is a schematic of a system for introducing textile treatment materials into a textile treatment system wherein the system utilizes a circulated dye-add loop in accordance with a process of the present invention;
FIG. 4 is a schematic of a syringe pump with mechanical piston and circulation pump for use in a system for introducing textile treatment materials into a textile treatment system in accordance with the present invention;
FIG. 5 is a schematic of a syringe pump with mechanical piston and magnetically coupled stirrer for use in a system for introducing textile treatment materials into a textile treatment system in accordance with the present invention;
FIG. 6 is a schematic of a syringe pump with mechanical piston and no agitation for use in a system for introducing textile treatment materials into a textile treatment system in accordance with the present invention;
FIG. 7 is a schematic of a syringe pump with an inert fluid piston and magnetically coupled stirrer for use in a system for introducing textile treatment materials into a textile treatment system in accordance with the present invention; and
FIG. 8 is a schematic of a syringe pump with an inert fluid piston and no agitation for use in a system for introducing textile treatment materials into a textile treatment system in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While the following terms are believed to be well-understood in the art, the following definitions are set forth to facilitate explanation of the invention.
The terms “supercritical fluid carbon dioxide” or “SCF-CO 2 ” are meant to refer to CO 2 under conditions of pressure and temperature which are above the critical pressure (P c =about 73 atm) and temperature (T c =about 31° C.). In this state the CO 2 has approximately the viscosity of the corresponding gas and a density which is intermediate between the density of the liquid and gas states.
The terms “near-critical liquid carbon dioxide” or “NCL-CO 2 ” are meant to refer to liquid CO 2 under conditions of pressure and temperature which are near the critical pressure (P c =about 73 atm) and temperature (T c =about 31° C.).
The term “textile treatment material” means any material that functions to change, modify, brighten, add color, remove color, or otherwise treat a textile material. Examples comprise UV inhibitors, lubricants, whitening agents, brightening agents and dyes. Representative fluorescent whitening agents are described in U.S. Pat. No. 5,269,815, herein incorporated by reference in its entirety. The treatment material is, of course, not restricted to those listed herein; rather, any textile treatment material compatible with the introduction and treatment systems is envisioned in accordance with the present invention.
The term “dye” is meant to refer to any material that imparts a color to a textile material. Preferred dyes comprise sparingly water-soluble or substantially water-insoluble dyes. More preferred examples include, but are not limited to, forms of matter identified in the Colour Index, an art-recognized reference manual, as disperse dyes. Preferably, the dyes comprise press-cake solid particles which has no additives.
The term “disperse dye” is meant to refer to sparingly water soluble or substantially water insoluble dyes.
The term “sparingly soluble”, when used in referring to a dye, means that the dye is not readily dissolved in a particular solvent at the temperature and pressure of the solvent. Thus, the dye tends to fail to dissolve in the solvent, or alternatively, to precipitate from the solvent, when the dye is “sparingly soluble” in the solvent at a particular temperature and pressure.
The term “hydrophobic textile fiber” is meant to refer to any textile fiber comprising a hydrophobic material. More particularly, it is meant to refer to hydrophobic polymers which are suitable for use in textile materials such as yarns, fibers, fabrics, or other textile material as would be appreciated by one having ordinary skill in the art. Preferred examples of hydrophobic polymers include linear aromatic polyesters made from terephathalic acid and glycols; from polycarbonates; and/or from fibers based on polyvinyl chloride, polypropylene or polyamide. A most preferred example comprises one hundred fifty denier/34 filament type 56 trilobal texturized yarn (polyester fibers) such as that sold under the registered trademark DACRON® (E.I. DuPont De Nemours and Co.). Glass transition temperatures of preferred hydrophobic polymers, such as the listed polyesters, typically fall over a range of about 55° C. to about 65° C. in SCF-CO 2 .
The term “crocking”, when used to describe a dyed article, means that the dye exhibits a transfer from dyed material to other surfaces when rubbed or contacted by the other surfaces.
Following long-standing patent law convention, the terms “a” and “an” mean “one or more” when used in this application, including the claims.
A critical step in the treating of textile materials in a supercritical fluid (e.g., SCF-CO 2 ) involves the introduction of textile treatment material (e.g., dyes and other chemicals). Current introduction methods employed in SCF-CO 2 textile dyeing systems are somewhat similar to those used in commercial aqueous dyeing systems.
An exemplary prior art system is shown schematically in FIG. 1 and generally designated 10 . As shown in FIG. 1, dyeing system 10 comprises a dyeing vessel 12 , a dyeing circulation loop 14 , a dyeing loop circulation pump 16 , a dye-add vessel 18 , and a series of SCF-CO 2 flow control valves 20 . Dye is introduced into system 10 by placing it in dye-add vessel 18 , which can accommodate flow of SCF-CO 2 . SCF-CO 2 flow is mediated by circulation pump 16 . At the appropriate time in the dyeing process, a portion of the main SCF-CO 2 flow (represented by arrows in FIG. 1) is diverted from dye circulation loop 14 via valves 20 into dye-add vessel 18 in order to effect dissolution of the dye. The diverted SCF-CO 2 flow, laden with dissolved dye, then re-enters and mixes with the main SCF-CO 2 flow in loop 14 for use in dyeing the textile material, which is placed in vessel 12 .
In marked contrast to prior art methods and systems, the textile treatment material introduction process and system of the present invention de-couple the textile treatment material dissolution process from the treatment process. The dye introduction rate is used to effect control over the dyeing rate in order to minimize non-uniform dyeing behavior, such as shading and streaking. As such, the dye introduction rate is varied to achieve amounts of dye in solution ranging from near zero up to the equilibrium value at each set of dyeing conditions (CO 2 density and temperature). Though a variety of solvents or carrier fluids can be used in the method and system of the present invention, the preferred preparation fluid is pure CO 2 in supercritical or near-critical liquid form.
The dye is introduced as a solution or suspension (dispersion) in SCF-CO 2 or NCL-CO 2 , depending on the required dye injection rate and the degree of solvency of SCF-CO 2 in the textile treatment system at the existing treatment conditions. As such, the use of surfactants or dispersing chemicals is not required in the introduction process and system of the present invention. However, co-solvents or surfactants may optionally be used to enhance dye solubility and dispersing agents may optionally be used to facilitate the establishment of stable suspensions of textile treatment materials in CO 2 .
Preferably, the textile treatment material introduction process and system of the present invention is used in conjunction with a method for treating a textile material using supercritical fluid carbon dioxide (SCF-CO 2 ). More preferably, the textile treatment material introduction method and system of the present invention are used in the treatment of a hydrophobic textile material, such as polyester, in SCF-CO 2 . However, application of the process and system of the present invention to other textile treatment processes and systems is contemplated.
For example, the method and system of the present invention also can be used with conventional aqueous dyeing processes. This is particularly the case with respect to treatment materials that are sparingly soluble in water. The textile treatment material introduction method and system of the present invention are used to predissolve such treatment materials, and the treatment materials are then introduced into a conventional aqueous dyebath. The use of environmentally hazardous organic co-solvents is thus avoided.
The textile treatment material introduction process and system of the present invention facilitate introduction of a textile treatment material, such as a dye, into a textile treatment process in that the treatment material is already dissolved or suspended when it contacts the solvent used in the treatment process. Thus, problems, such as agglomeration of particles, that have been observed in prior art processes, including particularly prior art SCF-CO 2 dyeing processes, are avoided.
Referring now again to the drawings, a preferred embodiment of the textile treatment material introduction system of the present invention is generally designated 30 in FIG. 2 . Referring to FIG. 2, system 30 introduces textile treatment materials dissolved or suspended in NCL-CO 2 or SCF-CO 2 into a textile treatment system 32 (similar shown in FIG. 1 ), which preferably comprises a SCF-CO 2 textile treatment system. System 30 comprises dye-add or preparation vessel 34 , positive-displacement metering pump 36 , line sections 38 and 40 , control valves 42 , 43 and 44 , filter 46 and return line 48 . Treatment system 32 comprises a treatment vessel 50 , a circulation loop 52 and a circulation pump 54 .
Continuing with reference to FIG. 2, a textile treatment material is placed in preparation vessel 34 , which is equipped with a stirring device 56 capable of thoroughly mixing the contents of vessel 34 . Stirring device 56 comprises a motor-driven fan, but may also comprise a motor-driven shaft, a rotatably mounted shaft, or any other suitable stirring device as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention. Other stirring devices include a fan, propeller or paddle that is magnetically coupled to a motor rather than coupled to the motor by a solid shaft. Another approach, though mechanically more difficult, comprises placing the dye bed within a holding container within the preparation vessel that is both permeable to flow of the SCF-CO 2 and capable of being agitated within the fluid. The permeable holding container can thus be adapted for rotation via the flow of SCF-CO 2 to provide mixing of the dye bed with the SCF-CO 2 . Such devices, and equivalents thereof, thus comprise “stirring means” and “mixing means” as used herein and in the claims.
Continuing with reference to FIG. 2, in operation the preparation vessel 34 of system 30 is sealed and charged with NCL-CO 2 or SCF-CO 2 . The amount of CO 2 initially charged and the state of CO 2 (i.e., NCL-CO 2 or SCF-CO 2 ) depends on the CO 2 density desired at the introduction conditions. If a co-solvent, surfactant or dispersing agent is to be used, it is charged along with the textile treatment material, or introduced with a metering pump (not shown in FIG. 2) into the preparation vessel 34 at some point in the textile treatment material preparation process. The contents of the preparation vessel 34 are then heated with mixing to the introduction conditions (i.e., CO 2 density and temperature), which is contemplated to be a pressure that is near the textile treatment system pressure.
Preferably, introduction system 30 , and particularly preparation vessel 34 , is isolated from treatment system 32 when the solution or suspension of textile treatment material is prepared. Control valves 42 , 43 and 44 are used to isolate preparation vessel 34 and thus can be opened and closed for reversibly isolating preparation vessel 34 . Any other suitable structure, such as other valves, piping or couplings, as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention may also be used to isolate, preferably to reversibly isolate, preparation vessel 34 . Such devices and structures, and equivalents thereof, thus comprise “isolation means” as used herein and in the claims.
Continuing with FIG. 2, depending on the introduction conditions and amount of textile treatment material present, the textile treatment material resides in a suspension or in a combination of solution and suspension. If introducing of a textile treatment material solution is desired, the fluid is removed from preparation vessel 34 via line section 38 , which is equipped with a filter 46 , and via control valve 42 . The filtering media of filter 46 has pore sizes predetermined from the particle size distribution and solubility characteristics of the textile treatment material. If introducing of a textile treatment material suspension or combination of textile treatment material solution and suspension is desired, the fluid is removed from the preparation vessel 34 via line section 40 and control valve 43 .
Continuing with reference to FIG. 2, positive-displacement metering pump 36 introduces the textile treatment material-laden NCL-CO 2 or SCF-CO 2 into the circulation loop 52 of treatment system 32 using a introducing rate profile that is consistent with producing uniformly-treated textile materials in minimum processing time. In a preferred embodiment, pump 36 shown in FIG. 2 comprises a positive displacement pump with a reciprocating piston. Other representative pumps include a syringe type pump employing a mechanical piston (FIGS. 4-6) as described below and a syringe type pump employing an inert fluid as a piston (FIGS. 7 and 8) as described below. Thus, devices such as pumps, nozzles, injectors, combinations thereof, and other devices as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention, and equivalents thereof, comprise “introducing means” as used herein and in the claims.
Mixing of the preparation vessel 34 is continued throughout the introduction cycle via mechanical stirring with stirring device 56 . Introducing of the textile treatment material-laden NCL-CO 2 or SCF-CO 2 occurs at an introduction point 58 in the circulation loop 52 where fluid shear is very high. For example, point 58 may lie before or after circulation pump 54 or in a mixing zone that contains static mixing elements (not shown in FIG. 2) in order to facilitate mixing with the treatment medium (e.g. SCF-CO 2 ) flowing in circulation loop 52 of treatment system 32 . The term “high fluid shear” refers to a turbulent flow or a flow with high rate of momentum transfer. Preferably, the term “high fluid shear” refers to a flow having a Reynolds number greater than 2300, and more preferably, greater than 5000.
When the textile treatment material is introduced as a solution from preparation vessel 34 into a SCF-CO 2 treatment system 32 , CO 2 makeup to introduction system 30 occurs via return line 48 . This action is taken in order to maintain the CO 2 density in introduction system 30 . Makeup of CO 2 involves opening the control valve 44 in the return line 48 such that SCF-CO 2 is diverted from circulation loop 52 to preparation vessel 34 in quantities sufficient to maintain the operating pressure of the introduction system 30 . Thus, control valve 44 and return line 48 , or any other suitable structure, such as other valves or couplings, as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention may be used to divert SCF-CO 2 to preparation vessel 34 . Such devices and structures, and equivalents thereof, thus comprise “diverting means” as used herein and in the claims.
When textile treatment material is dosed as a suspension into the treatment system 32 , introduction system 30 operates with full or partial CO 2 makeup via return line 48 . When textile treatment material introducing is performed without CO 2 makeup, the control valve 44 in return line 48 remains closed throughout the introduction cycle, and preparation vessel 34 is emptied of its contents during the introduction cycle. For introduction of suspension with full makeup, control valve 44 operates as described above. In the case of partial makeup, control valve 44 is operated intermittently to return SCF-CO 2 from circulation loop 52 to preparation vessel 34 ; i.e., preparation vessel 34 is partially emptied and then refilled with return SCF-CO 2 .
In the case of full or partial makeup to introduction system 30 when NCL-CO 2 is utilized in system 30 , the pressure of the returning SCF-CO 2 stream is reduced substantially across control valve 44 and return line 48 to match the near-critical liquid pressure in preparation vessel 34 .
Referring now to FIG. 3, an alternative embodiment of the textile treatment material introduction system 30 shown in FIG. 2 is disclosed and generally designated 60 . In alternative embodiment 60 , treatment materials are introduced in NCL-CO 2 or SCF-CO 2 into textile treatment system 62 , which preferably comprises a SCF-CO 2 textile treatment process. System 60 comprises dye-add or preparation vessel 64 , positive-displacement metering pump 66 , line sections 68 and 70 , control valves 72 , 73 and 74 , filter 76 and return line 78 . Treatment system 62 comprises a treatment vessel 80 , a circulation loop 82 and a circulation pump 84 .
Textile treatment material is placed in the preparation vessel 64 of system 60 . Preparation vessel 64 is equipped with a mixing loop 86 as shown in FIG. 3 . Thus, mixing of the preparation vessel 64 is continued throughout the introducing cycle via fluid circulation (demonstrated by arrows in FIG. 3) by circulation pump 88 through mixing loop 86 . Such devices and structures, and equivalents thereof, thus comprise “circulation means” and “mixing means” as used herein and in the claims. Other aspects of alternative embodiment 60 function as described above, including the introduction of treatment material at high fluid shear introduction point 90 .
Referring again to FIGS. 2 and 3, the method and system of the present invention also contemplate treating a textile material after introduction of a textile treatment material from the introduction system to the treatment system. The treatment system comprises a treatment vessel, a circulation loop, and a circulation pump. In a preferred embodiment, the treatment system comprises a SCF-CO 2 treatment system. A textile material, such as a hydrophobic textile fiber, is placed in the treatment vessel. A solution or suspension of treatment material is introduced into the treatment system at an introduction point from the introduction system as described above. The flow, represented by arrows in FIGS. 2 and 3, of the medium used in the treatment system (e.g. SCF-CO 2 flow) is mediated by the circulation pump. The circulation pump directs the flow of treatment medium, which now includes the solution or suspension of treatment material, along the circulation loop to the treatment vessel. In accordance with a preferred embodiment of the present invention, if a suspension is introduced into the treatment circulation loop, the conditions in the loop are such that the suspended material is rapidly dissolved in the treatment flow of supercritical fluid and not carried further as a suspension. Thus, the introduction is preferably made into an area of high shear to promote rapid mixing and dissolution of any undissolved treatment material particles. Within the vessel the treatment material contacts the textile material for a suitable time to impart the desired characteristics to the textile material.
Referring now to FIG. 4, an embodiment of a syringe pump suitable for use as an introducing means in accordance with the present invention is disclosed and is generally designated 100 . Syringe pump 100 comprises syringe pump body 102 , piston 104 , high pressure hose section 106 , circulation pump 108 , and high pressure hose section 110 . Syringe pump body 102 comprises an internal void space 112 in which piston 104 is slidably mounted. Piston 104 comprises an axial channel 114 through which the flow 116 (represented by arrows in FIG. 4) of SCF CO 2 travels within syringe pump 100 .
Continuing with FIG. 4, circulation pump 108 is connected to syringe pump body 102 via high pressure hose sections 106 and 110 . Circulation within syringe pump 100 is thus provided via circulation pump 108 . Treatment material-laden SCF CO 2 118 enters syringe pump 100 from a preparation system via line 120 and valve 122 . Circulation, or other type of agitation, is preferred if further dissolution of the dye is being accomplished or if an unstable suspension of the dye is being introduced. If circulation or agitation is not required (e.g., when introducing a stable suspension of the dye), an inert gas piston might be substituted for the mechanical piston, as discussed below and as shown in FIGS. 7 and 8. Syringe pump 100 then propels treatment material-laden SCF CO 2 118 into a treatment system via line 124 and valve 126 .
Referring now to FIG. 5, an alternative embodiment of a syringe pump suitable for use as an introducing means in accordance with the present invention is disclosed and is generally designated 150 . Syringe pump 150 comprises a syringe pump body 152 having an internal void space 154 wherein a syringe pump piston 156 is slidably mounted. Syringe pump piston 156 comprises an axially mounted stirrer shaft 158 having a stirrer shaft magnet 160 mounted at the end of stirrer shaft 158 proximate to stirrer magnet 162 . Stirrer magnet 162 is also mounted within syringe pump piston 156 , and propeller stirrer 164 extends from stirrer magnet 162 into the internal void space 154 of syringe pump 150 .
Continuing with FIG. 5, treatment material-laden SCF CO 2 166 enters syringe pump 150 from a preparation system via line 168 and valve 170 . Agitation of treatment material-laden SCF CO 2 166 is accomplished within syringe pump 150 via propeller stirrer 164 . Syringe pump 150 then propels treatment material-laden SCF CO 2 166 into a treatment system via line 172 and valve 174 .
Referring now to FIG. 6, yet another alternative embodiment of a syringe pump suitable for use as an introducing means in accordance with the present invention is disclosed and is generally designated 200 . Syringe pump 200 comprises a syringe pump body 202 having an internal void space 204 , and a piston 206 slidably mounted within the interval void space 204 of syringe pump body 202 . Treatment material-laden dye 208 enters syringe pump 200 from a preparation system via line 210 and valve 212 . Syringe pump 200 then propels treatment material-laden SCF CO 2 208 into a treatment system via line 214 and valve 216 .
Referring now to FIG. 7, another alternative embodiment of a syringe pump suitable for use as an introducing means in accordance with the present invention is disclosed and is generally designated 250 . Syringe pump 250 comprises pump body 252 having an internal void space 256 , and a high pressure fluid inlet line 254 . A stirrer shaft 258 and a stirrer shaft magnet 260 are mounted at the end of the syringe pump body 252 opposite the line 272 and valve 274 that connect pump 250 with a treatment system. A stirrer magnet 262 is also mounted in pump body 252 proximate to stirrer shaft magnet 260 . A propeller stirrer 264 extends into the internal void space 256 of pump body 252 from stirrer magnet 262 .
Continuing with FIG. 7, treatment material-laden SCF CO 2 266 enters pump 250 from a preparation system via line 268 and valve 270 . An inert material 278 (designated with a large arrow in FIG. 7 ), such as supercritical fluid nitrogen, is introduced into the internal void space 256 of pump body 252 via inlet line 254 while propeller stirrer 264 stirs the treatment material-laden SCF CO 2 266 . The in-flow inert material 278 drives treatment material-laden SCF CO 2 266 into a treatment system via line 272 and valve 274 .
Referring finally to FIG. 8, still another alternative embodiment of a syringe pump suitable for use as an introducing means in accordance with the present invention is disclosed and is generally designated 300 . Syringe pump 300 comprises pump body 302 having an internal void space 306 , and a high pressure inlet line 304 connected at the end of pump body 302 opposite from the line 314 and valve 316 that connect syringe pump 300 with a treatment system.
Continuing with FIG. 8, treatment material-laden SCF CO 2 308 enters syringe pump 300 from a preparation system via line 310 and valve 312 . An inert material 318 (designated with a large arrow in FIG. 8 ), such as supercritical fluid nitrogen, is introduced into the internal void space 306 of pump body 302 via high pressure line 304 . Inert material 318 thus drives treatment material-laden SCF CO 2 308 into a treatment system via line 314 and valve 316 .
The syringe pumps disclosed in FIGS. 4-8 can also be used in maintaining the SCF-CO 2 density in the preparation vessel by facilitating the addition of fresh SCF-CO 2 to the preparation vessel at the conditions in the preparation vessel without necessarily diverting SCF-CO 2 from the treatment system. For example, additional SCF-CO 2 can be introduced via high pressure lines 106 and/or 110 in FIG. 4 . This approach also adds additional SCF-CO 2 to the treatment system, and the treatment process is altered to include a different treatment process control strategy to accommodate the additional SCF-CO 2 . Thus, the pumps disclosed in FIGS. 4-8 also provide an alternative embodiment of the present invention in which SCF-CO 2 density is maintained in the preparation system without diverting SCF-CO 2 to the preparation vessel from the treatment system.
An advantage of the textile treatment material introduction process and system of the present invention is that it is used to introduce a variety of chemicals for treatment of a textile material. Thus, multiple operations can be performed concurrently or sequentially. For example, once a first textile treatment material, such as a dye, is introduced, the introducing system can be isolated and depressurized. Then, another textile treatment material, such as a UV inhibitor, can placed in the preparation vessel for introduction into the treatment system in accordance with the steps described herein above.
It will be understood that various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation—the invention being defined by the claims. | A process for introducing a textile treatment material into a textile treatment system, particularly a supercritical fluid carbon dioxide (SCF-CO 2 ) treatment system. The process includes the steps of providing a preparation vessel in fluid communication with a textile treatment system; loading a textile treatment material into the preparation vessel; dissolving or suspending the textile treatment material in near-critical liquid carbon dioxide or supercritical fluid carbon dioxide in the preparation vessel; and introducing the dissolved or suspended textile treatment material into the textile treatment system. The textile treatment material can be selected from a group including a brightening agent, a whitening agent and a dye. A system suitable for use in carrying out the process is also disclosed. | 3 |
TECHNICAL FIELD
The present invention relates to automatically correcting payee names and adjusting balances within the framework of managing personal finances, and is more particularly directed to managing links between payee names and reconciling ending balances with an on-line banking service.
BACKGROUND OF THE INVENTION
Managing personal finances can sometimes be very tedious and time-consuming. Paying bills, budgeting, investing, saving, and balancing checkbooks are areas that require planning, management, and skill. To assist in these tasks, financial software programs have been developed. These programs are generally designed to assist in understanding personal finances, as well as to make managing them easier.
For example, a financial software program can help a user track personal finances by storing financial information in a file on the user's personal computer. The user can update the file by connecting to an on-line database or banking service using the program and downloading transactions, account balances, and other financial information from the on-line database.
Typically, banks and financial institutions assign names to transactions that are sometimes unusual, complex, and/or confusing for a typical user to read and understand. A bank or financial institution offering credit or checking services also may assign multiple names to what the user may consider to be the same payee. For example, Chevron may be identified as Chevron #1234, Chevron #5678, and Chevron #9012, each representing different Chevron service stations. Because these Chevron service stations are treated like three separate payees due to the name assignment differences, the user may consider this payee name assignment confusing and not very useful. This issue can arise when the user wants to use the financial software program to determine the amount of money that he or she spends each month at Chevron. Thus, there is a need for an automated system for changing payee names presented by the user interface of a financial software program.
A financial software program typically allows a user to operate on a financial statement, such as a checking statement, which includes an initial financial amount or an “opening balance.” If the user enters an opening balance within the financial statement, there exists the possibility that a different opening balance may downloaded when the user connects to an on-line financial service. Assuming that the user-entered opening balance amount is different from the opening balance amount downloaded from the on-line database, there is no mechanism within prior financial software programs to correct the user-entered opening balance amount in response to downloading the on-line financial statement. By failing to reconcile the differences between the user-entered and downloaded opening balances, the ending balance in the user's file for the financial statement may also be incorrect. This can result in inaccurate financial records in the absence of a mechanism to synchronize user data with downloaded data.
For example, the “QUICKEN” program, which is marketed by Intuit, Inc. of Menlo Park, Calif., is a financial software program that allows a user to download financial statement data from an on-line service. The opening balance for the QUICKEN program is typically represented as the first transaction in the user's account. It is understood that the QUICKEN program, however, does not update this opening balance transaction in response to downloading on-line financial data containing another opening balance amount. Therefore, the user can potentially maintain an incorrect ending balance as a result of downloading on-line financial information.
In view of the foregoing, there exists increased chances for errors when a user of a financial software program attempts to synchronize or merge data from the user's file with data downloaded from the on-line banking service. There is a further need for a system to assist a user in the synchronization of the financial data from the user's file with the data from the on-line banking service. There is yet a further need for a convenient and efficient system for changing payee names presented by the user interface of a financial software program. There is also a need for a system that reconciles ending balances and corrects an opening balance in a user's file after downloading an on-line financial statement to maintain a correct ending balance in the user's file.
SUMMARY OF THE INVENTION
The present invention satisfies the above-described needs by providing a system for replacing a first parameter of a field in a display screen area with an alternative parameter. Generally described, a first field parameter within a field of the display screen is displayed on a display device. An indication is received that the first field parameter has been changed to the alternative field parameter, also referred to as a second field parameter. In response to this indication, a link is created between the first field parameter and the second field parameter for each occurrence of the first field parameter. Responsive to the link between the first field parameter and the second field parameter, the second field parameter is displayed in the place of the first field parameter within the field of the display screen. In the context of a financial statement, first field parameters are typically actual or original payee names associated with financial transactions, and second field parameters are alternative payee names preferred by the user.
Links between field parameters of the display screen field can be managed to support the automated substitution within the field of a second field parameter for a first field parameter. A link is an aliasing mechanism in a data structure that connects a first field parameter, i.e., the original payee name, to a second field parameter, i.e., the preferred payee name. This link management system can automatically create, delete or change a link in response to a change of a field parameter. For example, a link is created when a preferred payee name is designated as the substitute for an original payee name. The link points to the preferred payee name for each occurrence of the original payee name. Based on this link, the preferred payee name can be displayed without user intervention in the place of the original payee name in the field of the display screen. This substitution can occur without the user seeing the original payee name within the display screen field.
More particularly described, a system is provided for automatically correcting different payee names resulting from the electronic transfer of financial data for use by a financial program operating on a user-created financial statement. The system can automatically rename payees from the assigned bank payee name (original payee name) to a payee name the user prefers (preferred payee name). In response to downloading an on-line financial statement comprising original payee names from an on-line banking service, a first payee name can be displayed to the user in a field of a display screen area. A determination is made that the first payee name has been changed to a substitute payee name. In response, the first payee name is replaced with the substitute payee name within the field of the display screen area for each occurrence of the first payee name.
To eliminate potential user confusion, this aspect of the present invention allows the user to change the original payee name provided by the on-line banking service to any “substitute” name the user prefers. For example, Chevron may be identified as Chevron #1234, Chevron #5678, and Chevron #9012, each representing different Chevron service stations, by an on-line financial service. In this case, the user can decide to change all three original payee names to the preferred payee name of Chevron. By doing so, when the user downloads a transaction having one of the original payee names, in this case, Chevron #1234, Chevron #5678, or Chevron #9012, the inventive system will automatically display the preferred payee name, i.e., Chevron, without user intervention.
Another aspect of the present invention provides a system for reconciling an ending balance in a personal data store with an on-line financial statement provided by an on-line banking service by correcting an opening balance in the personal data store. This automated balance adjustment system can reconcile an ending balance derived from the user's file or a personal data store with the ending balance derived from the on-line banking service before the data is downloaded. This may require correcting the opening balance taken from a user's file so that, after an account has been taken for all transactions, the ending balance in the user's file matches the ending balance in an on-line financial statement provided by the on-line banking service.
In connection with this aspect of the present invention, the personal data store is displayed having an opening balance, transactions organized by date, and the ending balance. The on-line financial statement, which contains transactions organized by date, an ending period, and an ending balance, is then downloaded. Next, the earliest dated transaction in the personal data store is compared to the earliest dated transaction in the on-line financial statement to determine whether the earliest dated transaction in the personal data store is later than the earliest dated transaction in the on-line financial statement. If the earliest dated transaction in the personal data store is not later than the earliest dated transaction in the on-line financial statement, then a determination is made as to whether any transactions have been downloaded into the personal data store. If none of the transactions of the on-line financial statement have been downloaded into the personal data store, then a correct opening balance is calculated. The correct opening balance is then displayed. Preferably, a prompt is displayed indicating that the opening balance has changed to the correct opening balance. The correct opening balance is preferably calculated by subtracting the sum of all transactions in the on-line financial statement from the ending balance in the on-line financial statement.
More particularly described, a determination can be made whether any transactions have been downloaded into the personal data store. The ending balance in the on-line financial statement is compared to the transactions in the personal data store to determine whether any transaction date in the personal data store is the same as the ending period. If so, then all transactions in the personal data store are searched for downloaded transactions in the personal data store starting from the transaction having the same date as the ending period moving backward, one transaction at a time, until the earliest dated transaction in the personal data store is reached. Similarly, if there is no transaction date that is the same as the ending period, then the closest transaction date in the personal data store that occurs before the ending period is located, and all transactions are searched for any downloaded transactions in said personal data store from the closest transaction date backward, one transaction at a time, to the earliest dated transaction in the personal data store. Consequently, each downloaded transaction is designated by a flag to indicate which transaction of the plurality of transactions has been downloaded.
In view of the foregoing, the present invention provides an improved system for assisting the user in the synchronization of the financial data from the user's file with the data from the on-line banking service. The present invention also provides an automated system for changing payee names. In addition, the present invention provides an improved system for maintaining payee name links by automatically creating, deleting or changing links. The present invention also provides a system for automatically reconciling ending balances without manual intervention.
These and other objects, features, and advantages of the present invention may be more clearly understood and appreciated from a review of the following detailed description of the disclosed embodiments and by reference to the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a personal computer that provides an exemplary operating environment for the exemplary embodiment of the present invention.
FIG. 2 is a screen display illustrating an initial display screen in accordance with the exemplary embodiment of the present invention.
FIG. 3 is a screen display illustrating a home banking display screen in accordance with the exemplary embodiment of the present invention.
FIG. 4 is a screen display illustrating a selection of the Statements tab in accordance with the exemplary embodiment of the present invention.
FIG. 5 is a screen display illustrating a financial statement window in accordance with the exemplary embodiment of the present invention.
FIG. 6 a is a screen display illustrating an update dialog box in accordance with the exemplary embodiment of the present invention;
FIG. 6 b is a screen display illustrating an advancement to a second transaction after selection of a Next button in accordance with the exemplary embodiment of the present invention.
FIG. 6 c is a screen display illustrating a change from the name “Other debit” to “Veda” in accordance with the exemplary embodiment of the present invention.
FIG. 6 d is a screen display illustrating an automatic substitution of an original payee name to a preferred payee name in a third transaction in accordance with the exemplary embodiment of the present invention.
FIG. 7 is a flow diagram illustrating the steps that a user follows to change an original payee name to a preferred payee name in accordance with the exemplary embodiment of the present invention.
FIG. 8 is a flow diagram illustrating the steps for managing links in response to user-provided input in accordance with the exemplary embodiment of the present invention.
FIG. 9 is a diagram illustrating the data structure for the automatically correct payee name feature containing a dummy payee table and an active payee table in accordance with the exemplary embodiment of the present invention.
FIG. 10 is a flow diagram illustrating the steps taken before displaying a single transaction in accordance with the exemplary embodiment of the present invention.
FIG. 11 is a flow diagram illustrating the steps that a user follows to reconcile an ending balance in a personal data store in accordance with the exemplary embodiment of the present invention.
FIG. 12 is a flow diagram illustrating the steps taken to determine when to calculate an opening balance in accordance with the exemplary embodiment of the present invention.
DETAILED DESCRIPTION
The present invention is directed toward a system for synchronizing data from an on-line banking service with a personal data store utilizing Automatically Correct Payee Name and Automatic Balance Adjustment. In one embodiment, the invention is incorporated into a financial software application program entitled “MICROSOFT MONEY 5.0”, (hereinafter “MONEY”) marketed by Microsoft Corporation of Redmond, Wash. Briefly described, the program allows a user to keep track of personal finances by storing financial information in a file on the user's personal computer. The user can update the file by connecting to an on-line database or banking service using the MONEY program and downloading transactions, account balances, and other financial information from the on-line banking service into the user's file. Automatically Correct Payee Name and Automatic Balance Adjustment will be described in greater detail herein below with respect to FIGS. 2-12 , wherein like elements are represented by like numerals throughout the several figures.
Now turning to FIG. 1 , an exemplary operating environment in accordance with the exemplary embodiment of the present invention is now described.
Exemplary Operating Environment
FIG. 1 and the following discussion are intended to provide a brief, general description of a suitable computing environment in which the invention may be implemented. While the invention will be described in the general context of an application program that runs on an operating system in conjunction with a personal computer, those skilled in the art will recognize that the invention also may be implemented in combination with other program modules. Generally, program modules include routines, programs, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the invention may be practiced with other computer system configurations, including hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframe computers, and the like. The invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
With reference to FIG. 1 , an exemplary system for implementing the invention includes a conventional personal computer 20 , including a processing unit 21 , a system memory 22 , and a system bus 23 that couples the system memory to the processing unit 21 . The system memory 22 includes read only memory (ROM) 24 and random access memory (RAM) 25 . A basic input/output system 26 (BIOS), containing the basic routines that help to transfer information between elements within the personal computer 20 , such as during start-up, is stored in ROM 24 . The personal computer further includes a hard disk drive 27 , a magnetic disk drive 28 , e.g., to read from or write to a removable disk 29 , and an optical disk drive 30 , e.g., for reading a CD-ROM disk 31 or to read from or write to other optical media. The hard disk drive 27 , magnetic disk drive 28 , and optical disk drive are connected to the system bus 23 by a hard disk drive interface 32 , a magnetic disk drive interface 33 , and an optical drive interface 34 , respectively. The drives and their associated computer-readable media provide nonvolatile storage for the personal computer 20 . Although the description of computer-readable media above refers to a hard disk, a removable magnetic disk and a CD-ROM disk, it should be appreciated by those skilled in the art that other types of media which are readable by a computer, such as magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, and the like, may also be used in the exemplary operating environment.
A number of program modules may be stored in the drives and RAM 25 , including an operating system 35 , one or more application programs 36 , other program modules 37 , and program data 38 . A user may enter commands and information into the personal computer 20 through a keyboard 40 and pointing device, such as a mouse 42 . Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 21 through a serial port interface 46 that is coupled to the system bus, but may be connected by other interfaces, such as a game port or a universal serial bus (USB). A monitor 47 or other type of display device is also connected to the system bus 23 via an interface, such as a video adapter 48 . In addition to the monitor, personal computers typically include other peripheral output devices (not shown), such as speakers or printers.
The personal computer 20 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 49 . The remote computer 49 may be a server, a router, a peer device or other common network node, and typically includes many or all of the elements described relative to the personal computer 20 , although only a memory storage device 50 has been illustrated in FIG. 1 . The logical connections depicted in FIG. 1 include a local area network (LAN) 51 and a wide area network (WAN) 52 . Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
When used in a LAN networking environment, the personal computer 20 is connected to the LAN 51 through a network interface 53 . When used in a WAN networking environment, the personal computer 20 typically includes a modem 54 or other means for establishing communications over the WAN 52 , such as the Internet. The modem 54 , which may be internal or external, is connected to the system bus 23 via the serial port interface 46 . In a networked environment, program modules depicted relative to the personal computer 20 , or portions thereof, may be stored in the remote memory storage device. It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers may be used.
Automatically Correct Payee Name
With continuing reference to FIG. 1 and now turning to FIGS. 2-6 d , the user's environment for the exemplary embodiment of the present invention will be described by utilizing screen displays generated by the preferred application program.
FIGS. 2-6 d illustrate the screen displays provided by the preferred program module to allow the user to change a payee name provided by a bank to a payee name that the user prefers. For purposes of this discussion, the terms “original payee name” and “preferred payee name” are used to describe a name provided by a bank and a name that the user prefers, respectively.
FIG. 2 depicts an initial display screen 100 that is displayed on the monitor 47 . The display screen 100 includes the display area 102 , a series of general operational choice menus 103 a - d , operational buttons 104 a - c and contents icons 105 a - i . The display screen 100 is displayed on the monitor 47 by the preferred program module after the user selects the preferred program module from among the application programs 36 , which is stored in the system memory 22 of the computer 20 .
Because this aspect of the invention focuses on changing payee names, demonstration of this aspect is implemented using the Home Banking content displayed in the display screen area 102 of the display screen 100 . The Home Banking content provides information about the user's accounts, banking statements, payments in progress, and contact information. The Home Banking content allows the user to connect to an on-line banking service for conducting general banking functions such as making payments, transferring money between accounts, and so on. The user selects the Home Banking content by clicking onto the Home Banking icon 105 c using the mouse 42 .
Now turning to FIG. 3 , after the user clicks onto the Home Banking icon 105 c using the mouse 42 , a home banking display screen 120 is displayed on the monitor 47 in accordance with the exemplary embodiment of the present invention. The home banking display screen 120 contains a series of tabs 107 a - e , each containing a list of items containing information associated with each tab. For purposes of this discussion, emphasis will be placed on the Statements tab 107 b for demonstration of the ACPN feature. To obtain a list of the financial statements for each account, the user simply clicks onto the Statements tab 107 b using the mouse 42 . After doing so, the Statements tab 107 b and associated content move to the forefront of the home banking display screen 120 , as shown in FIG. 4 .
Now turning to FIG. 4 , a screen display depicting selection of the Statements tab 107 b will now be described. The statements tab 107 b contains a list of bank accounts 109 a , an on-line financial statement 109 b for each account, the number of transactions 109 c for each on-line financial statement, and a current balance 109 d for each account. To view an on-line financial statement, first the user selects one of the listed bank accounts using the mouse 42 . The desired bank account is highlighted on the home banking display screen 120 . For example, the user can select DPGTY Credit Card 112 . Next, the user selects a Read Statement button 110 located on the right side of the home banking display screen 120 using the mouse 42 . The Read Statement button 110 allows the user to view the selected on-line financial statement on the home banking display screen 120 . Once the Read Statement button 110 is selected, a financial statement window is displayed on top of the home banking display screen 120 , as shown in FIG. 5 .
Now referring to FIG. 5 , a screen display illustrating a financial statement window in accordance with the exemplary embodiment of the present invention will be described. The financial statement window 125 contains a list of all of the transactions 127 that were downloaded from the on-line banking service associated with the selected bank account 129 . In this case, the transactions 127 associated with the DPGTY Credit Card account 129 are displayed in the financial statement window 125 . The on-line financial statement includes information such as the date 130 of each transaction, the payee name 132 , the charge 134 or credit 136 , the statement date 138 , and the closing balance 140 . The information in the on-line financial statement comes directly from the on-line banking service and cannot be changed when presented in this format. For example, the payee name 132 for each transaction is “Other debit” and will always bear this payee name each time the on-line financial statement is downloaded from the on-line banking service. However, the user may desire to change the payee name when viewing the list of transactions on an individual basis. This process will be described in greater detail below with respect to FIGS. 6 a - 6 d.
Referring back to FIG. 5 , after viewing the on-line financial statement, the user may want to update the user's file by incorporating the data from the on-line financial statement. To update the user's file, the user selects an Update Account Register button 142 located in the lower right corner of the financial statement window 125 . The Update Account Register button 142 allows the user to view the transactions 127 listed in the financial statement window 125 on an individual basis. To do so, the user clicks on the Update Account Register button 142 using the mouse 42 . Once the Update Account Register button 142 is selected, the financial statement window 125 is no longer displayed, and an update dialog box 150 is displayed on top of the home banking display screen 120 , as illustrated by FIG. 6 a.
With continuing reference to FIGS. 1-5 and now turning to FIGS. 6 a - 6 d , the update dialog box 150 will now be described. In FIG. 6 a , the update dialog box 150 displays one transaction at a time for downloading into the user's file. The update dialog box 150 contains a transaction number indicator 152 to keep track of which transaction is being displayed and a total number of transactions 154 for the financial statement. In this example, transaction 1 of 20 is displayed. The update dialog box 150 also contains a name of the charge account 156 , a payee name 158 for the transaction, a date 160 for the transaction, and an amount 162 of the transaction.
The user typically reviews each transaction for accuracy. If a transaction is accurate and does not already appear in the user's file, the user then decides whether to download the transaction or postpone downloading the transaction into the user's file. To postpone downloading transactions, the user can select a Postpone button 166 using the mouse 42 . Once the Postpone button 166 is selected the downloading process is terminated, the update dialog box 150 is no longer displayed, and the home banking display screen 120 returns to the forefront on the monitor 47 of the computer 20 , as shown in FIG. 4 . On the other hand, to download the transaction into the user's file, the user can select a Next button 164 using the mouse 42 . Once the transaction is downloaded into the user's file, the next transaction will be displayed in the update dialog box 150 , as shown in FIG. 6 b.
Now referring to FIG. 6 b , a screen display illustrating advancement to the next transaction after selection of a Next button is shown in an update dialog box. In FIG. 6 b , the update dialog box 150 is displayed on top of the home banking display screen 120 , as previously described with respect to FIG. 6 a . In this example, the transaction number indicator 152 indicates that the displayed transaction is now transaction 2 of 20 . In transaction 2 , the date and amount of the transaction is different from the date and amount of transaction 1 . ( FIG. 6 a ) Of particular importance to this discussion is the payee name 158 for the transaction. In this example, the payee name 158 is “Other debit”, which is the same payee name as the payee name in transaction 1 .
Referring back to FIG. 6 b , the user may decide to change the payee name to a name that the user prefers. For example, the user may decide to change the name “Other debit” to “Veda” so that the user can keep up with all charges to “Other debit” under a name that is more meaningful to the user. Changing the payee name is accomplished by selecting the payee name that the user wants to change using the mouse 42 . In this example, the user wants to change <Other debit> 158 . The user clicks the mouse 42 on “Other debit” 158 . Once the user clicks the mouse 42 on the payee name, the payee name is highlighted.
Referring to FIG. 6 c , the user simply enters the name <Veda> in the space provided next to the phrase “Pay to:” using the keyboard 40 . Once the new name 170 is entered, the payee name change is displayed. Each time the original payee name occurs within the dialog box showing individual transactions, the preferred payee name is automatically substituted for the original payee name without user interaction. The change occurs “behind the scenes” for all occurrences of the original payee name, and the user only sees the preferred payee name in the individual transactions.
For example, referring to FIG. 6 d , the payee name for transaction indicator 182 ( 3 of 20 ) already has a payee name “Veda” 180 . If a comparison is made between this payee name ( FIG. 6 d ) and the third payee name in the list in FIG. 5 , it is noted that while “Other debit” appears in the list ( FIG. 5 ), it has been automatically substituted by “Veda” in the individual transaction ( FIG. 6 d ). However, this substitution does not occur in the on-line financial statement. That is, whenever the user downloads the on-line financial statement from the on-line banking service, the payee names will be the original payee names provided by the bank and never the preferred payee names chosen by the user.
To reiterate, FIGS. 2-6 d represent a typical environment for using the ACPN feature. Once a payee name is changed, this information is stored in the memory of the preferred program module memory. Each time the old or original payee name occurs within the dialog box showing individual transactions, the new or preferred payee name is automatically substituted for original payee without user interaction. This process is performed “behind the scenes” within the ACPN feature, and the user never sees the original payee name displayed again, with one exception. Before the user downloads data in the user's file from an on-line banking service, the user will initially see the original payee names. However, once the user downloads the data from the on-line service into the user's file, the preferred payee names will automatically appear for each transaction without user interaction.
Now turning to FIGS. 7-10 , implementation of the data structure and user interface for the ACPN feature will be described in greater detail. The environment described herein and for the remainder of the discussion involves connection to an on-line banking service and use of an on-line financial statement provided by the on-line banking service.
FIG. 7 is a flow diagram that illustrates the steps that a user follows to change an original payee name to a preferred payee name in accordance with the exemplary embodiment of the present invention. The process begins at the START step 200 by turning on the computer 20 and selecting the preferred program module for supporting the computer-implemented process for changing a payee name.
In step 202 , a connection is made to an on-line banking service via modem 54 . A list of all the transactions is then displayed in step 204 . In step 206 , an option to view a single transaction is selected. The single transaction is then displayed in step 208 . Next, a determination is made, in step 210 , as to whether there is a desire to change the payee name provided in the transaction. If there is a desire to change the payee name, the “YES” branch is followed to step 214 ; otherwise, the “NO” branch is followed to the END step 212 . In step 214 , the payee name field is selected by clicking the mouse 42 on the payee name field. Next, in step 218 , the payee name is changed to a preferred payee name in response to user-provided input. The preferred payee name is then displayed in the payee name field in step 220 . The payee name change process terminates at the END step 212 .
The process of changing an original payee name to a preferred payee name is implemented in a one-to-one mapping arrangement by using linking mechanisms. Each time the user changes a payee name, a link is either created, changed, or eliminated. With respect to the ACPN feature, links serve dual purposes. One purpose of a link is to map the original payee name to the preferred payee name so that the link can be followed from the original payee name to the preferred payee name. A second purpose of a link is to act as a flag for the original payee name. This second purpose will be described in greater detail later with respect to FIG. 9 . In essence, the preferred program module is capable of automatically managing links by internally determining when a link should be created, changed, or eliminated in response to user-provided input. It will be appreciated by one skilled in the art that the management of links is not limited to use with financial transactions, in general, and payee names, in particular, but can also apply to any action or transaction requiring links between one field and another field.
Referring to FIG. 8 , the method by which the computer manages links during the payee name changing process will now be described. FIG. 8 is a flow diagram illustrating the steps for automatically creating, changing, and eliminating links in response to a user changing a payee name. At the START step 300 , the computer parameters are initialized, the preferred application program is selected, and the on-line banking service is connected via modem 54 .
A single transaction is displayed in step 302 , in response to user-provided input. A determination is made as to whether there is a desire to change the payee name as displayed in the transaction, in step 304 . If there is a desire to change the payee name, the “YES” branch is followed to step 308 ; otherwise, the “NO” branch is followed to the END step 306 . In step 308 , the preferred payee name is provided by the user according to the method described with respect to FIG. 7 .
After the name is provided, a determination is made, in step 310 , as to whether a link currently exists with respect to the payee name that the bank had originally provided. If a link already exists between the original payee name and an old preferred payee name, the “YES” branch is followed to step 311 ; otherwise, the “NO” branch is followed to step 312 . In step 311 , the link that already exists between the original payee name and the old preferred payee name is eliminated. In step 319 , a link is created from the original payee name to the preferred payee name, which is now the new preferred payee name. In step 320 , a comparison is made between the preferred payee name and the original payee name. Next, a determination is made, in step 322 , as to whether the preferred payee name is the same as the original payee name. If the payee names are the same, the “YES” branch is followed to step 328 ; otherwise, the “NO” branch is followed to step 326 . In step 328 , the link from the original payee name to the preferred payee name is eliminated. Once the link is eliminated, the original payee name is displayed in step 330 . The process terminates at the END step 306 . If the payee names are not the same, in step 326 ′, the preferred payee name is displayed on the display screen. The process then terminates at the END step 306 .
If a link does not currently exist with respect to the original payee name, the original payee name is then stored in a dummy payee field in step 312 . Dummy payee fields will be described in greater detail below with respect to FIG. 9 . Referring back to FIG. 8 , in step 314 , a link is created from the original payee name to the preferred payee name. The preferred payee name is then displayed on the display screen in step 316 . The process terminates at the END step 306 .
Now turning to FIG. 9 , a diagram illustrating the data structure for automatically correct payee containing a dummy payee table and an active payee table are shown in accordance with the exemplary embodiment of the present invention. In FIG. 9 , the data structure 400 is designed to manage the ACPN feature. The active payee table 410 contains all of the active payee name field parameters 405 a . In this case, the field parameters are all originating payee names 405 a —i.e. Xa, Xb, Xc, Xd, Xe, Xf, and Xg. The dummy payee table 420 contains in a dummy field 415 , all deleted payee names (A, B, C, Xb*, M, N, and O) and the active payee names having links 430 (Xc, Xf, and Xg) to preferred payee names 405 b (Y, Yg). When an original payee name 405 a is changed by the user, in a manner previously described, the original payee name 405 a is automatically stored in the dummy field 415 and a link 430 is created to point to the preferred payee name 405 b . The link 430 also serves as a flag indicating that the field parameter in the dummy field 415 is special and should not be erased during a database clean-up.
Before an individual transaction is displayed, the dummy payee table 420 is searched first to find an exact match for the original payee name in the transaction. If an exact match is found, the program module looks for the link or flag 430 . If there is a link 430 , the program module follows that link 430 to the preferred payee name 405 b and displays it. For example, suppose the original payee name in the transaction is Xf. In this example, Xf is found in the dummy payee table 420 , Xf has a link 430 , and Xf points to the preferred payee name 405 b , Yf. Therefore, Yf is automatically displayed in the individual transaction.
If an exact match is found in the dummy payee table 420 , but the match does not have a flag or link 430 , or if an exact match is not found in the dummy payee table 420 , then the active payee table 410 is searched next to find an exact match. If an exact match is found, the original payee name is displayed. However, if an exact match is not found, the original payee name is first displayed in the individual transaction and once accepted by the user, the original payee name is then added to the active payee table 410 . A more concise description of the single transaction display process is provided below with respect to FIG. 10 .
Referring now to FIG. 10 , a method by which a computer automatically displays a single transaction in response to user-provided input is provided in accordance with the exemplary embodiment of the present invention. FIG. 10 is a flow diagram illustrating the steps performed by a computer 20 to display a single transaction. At the START step 500 , the computer parameters are initialized, the preferred application program is selected, and the on-line banking service is connected via modem 54 .
A list of all transactions is displayed in step 504 . A selection is made, in step 506 , requesting the display of a single transaction. In step 508 , a dummy payee table search is performed to find an exact match for an original payee name associated with a specific transaction. Next, a determination is made as to whether an exact match is located in the dummy payee table in step 510 . If an exact match is located, the “YES” branch is followed to step 514 ; otherwise, the “NO” branch is followed to step 512 . In step 514 , a determination is made as to whether the matched payee name has a flag. If so, the “YES” branch is followed to step 524 ; otherwise, the “NO” branch is followed to step 512 . In step 524 , the matched payee name in the dummy payee table points to a preferred payee name. Next, the preferred payee name is displayed in the single transaction in step 526 . The process terminates at the END step 522 .
If an exact match is not located in the dummy payee table or the matched payee name from the dummy payee table does not have a flag, then an active payee table search is performed to find an exact match for the original payee name in step 512 . In step 516 , a determination is made as to whether an exact match of the original payee name is located in the active payee table. If so, the “YES” branch is followed to step 520 ; otherwise, the “NO” branch is followed to step 517 . In step 520 , the original payee name is displayed in the single transaction. The display process terminates at the END step 522 .
If the active payee table does not contain an exact match of the original payee name, the original payee name is displayed on the display screen in the single transaction in step 517 . Next, in step 518 , user-provided input is received accepting the transaction. The original payee name is then added to the active payee table in step 519 . The display process terminates at the END step 522 .
In summary, the ACPN feature represents an exemplary embodiment of the present invention. The APCN feature is designed to automatically rename parameters presented within a field of a display screen, such as substituting payees from the assigned bank payee name (original payee name) to a payee name the user prefers (preferred payee name). The ACPN feature is designed such that it automatically creates, deletes or changes a link whenever the user changes a field parameter, in this case the payee name, in the payee name field. When the original payee name is a part of a transaction or appears elsewhere within the framework of the preferred program module, the link points to the preferred payee name. Consequently, the preferred payee name is automatically displayed, thereby replacing the original payee name without presenting the original payee name within the display screen field.
Another embodiment of the present invention provides a system for managing a link between field parameters within a field for a transaction, and thereafter displaying one of the field parameters based on the creation or elimination of the link. A first field parameter is changed to a third field parameter within the field. A determination is made as to whether the first field parameter already has a link to a second field parameter. If the first field parameter does not already have a linking mechanism, then a link is created from the first field parameter to the third field parameter, and the third field parameter is displayed. However, if the first field parameter already has a link to the second field parameter, then the link from the first field parameter to the second field parameter is eliminated, and a link from said first field parameter to the third field parameter is created. A determination is then made as to whether the first field parameter is the same as the third field parameter. If the first field parameter is not the same as the third field parameter, then the third field parameter is displayed. On the other hand, if the first field parameter is the same as the third field parameter, then the link between the first field parameter and the third field parameter is eliminated, the third field parameter is deleted, and therefore, the first field parameter is displayed.
Maintenance of changes in field parameters can be performed within a data structure by utilizing linking mechanisms. The data structure can be used for managing the display of a first field parameter or a second field parameter on a display device, and comprises a dummy table and an active table. The dummy table located in the data structure contains a plurality of field parameters, wherein at least two of the field parameters are linked together with a link. A first determination is made as to whether the first field parameter is located in the dummy table. If so, then a second determination is made as to whether the first field parameter in the dummy table has a link, wherein the link is located between the first field parameter and the second field parameter. If a link is found, then the link is used to point to the second field parameter, and the second field parameter is provided for display on the display device. However, if the first field parameter is not located in the dummy table or the first field parameter is located in the dummy table but does not have the link between the first field parameter and the second field parameter, then a third determination is made as to whether the first field parameter is located in the active table located in the data structure, wherein the active table contains a plurality of field parameters. If the first field parameter is located in the active table, then the first field parameter is provided for display on the display device. On the other hand, if the first field parameter is not located in the active table, then the first field parameter is displayed on the display device before the first field parameter is added to the active table.
Automated Balance Adjustment (ABA)
In another embodiment of the present invention, a method is provided for reconciling an ending balance in a user's file with an on-line financial statement provided by an on-line banking service. Implementation-wise, it is necessary to correct an opening balance in the user's file so that downloaded transactions provide an ending balance in the user's file that is consistent with the ending balance in the on-line financial statement.
Transactions in the user's file and in the on-line financial statement are categorized by date. These dates are used to determine whether an opening balance in the user's file has to be corrected. Generally described, the test for making this determination is as follows: if (1) the earliest transaction date in an on-line financial statement is earlier than or the same as the earliest transaction date in the user's file and (2) there have been no downloaded transactions from the on-line financial statement into the user's file from the closing period of the on-line financial statement up to the earliest dated transaction in the user's file, then the opening balance has to be corrected to reconcile the ending balance. In other words, if either (1) or (2) is responded to negatively, then the opening balance does not have to be corrected and the ending balance in the user's file is fine. This process of reconciling ending balances is described in greater detail below with respect to FIG. 12 .
In cases where the opening balance has to be corrected, the following formula (A) is used to calculate the correct opening balance.
OB=EB −( T+Tn+ . . . +Tn+ 1). (A)
Where, OB represents the opening balance of the user's file; EB represents the ending balance of the on-line financial statement; and (T+Tn+ . . . +Tn+1) represents the sum of all transactions in the on-line financial statement.
Once the opening balance is corrected, a prompt is displayed to inform the user that the opening balance has been corrected.
This process is automatically performed each time the user chooses an option to download data from an on-line banking service into the personal data store. The advantage of the ABA feature is that the user no longer has to worry about the task of maintaining an accurate ending balance, because the ABA feature automatically performs this function for the user.
Now turning to FIGS. 11 and 12 , the user interface and computer-implemented processes for automatic balance adjustment will be described.
Referring to FIG. 11 , a flow diagram illustrating the steps required for reconciling an ending balance in a user's file is provided in accordance with the exemplary embodiment of the present invention. At the START step 600 , the computer parameters are initialized and the preferred application program is selected.
In step 602 , the user's file is displayed. Next, in step 604 , a connection is made to the on-line banking service via modem 54 . Once the connection is made, in step 606 , a financial statement from the on-line banking service is displayed. In step 608 , an option to synchronize the information in the user's file with the data from the on-line financial statement is selected. Once this option is selected, the ending balance is automatically reconciled, in step 610 . Next, in step 612 , a determination is made as to whether the opening balance in the user's file has changed after the ending balance has been reconciled. If the opening balance has changed, the “YES” branch is followed to step 614 ; otherwise, the “NO” branch is followed to the END step 616 . In step 614 , a prompt appears on the display screen indicating that the opening balance in the user's file has changed. The process terminates at the END step 616 .
Now turning to FIG. 12 , the method by which a computer 20 automatically adjusts an opening balance in a user's file to produce an accurate ending balance will now be described. FIG. 12 is a flow diagram of the steps involved for automatic balance adjustment in accordance with the exemplary embodiment of the present invention. At the START step 700 , the computer parameters are initialized, the preferred application program is selected, and an on-line banking service is connected via modem 54 .
The user's file having an opening balance is displayed on the display screen of the monitor 47 , in step 702 . In step 703 , an on-line financial statement is displayed on the display screen of the monitor 47 . Next, in step 704 , an option is selected for downloading the on-line financial statement into the user's file. After downloading the on-line financial statement, but prior to entering transactions into the user's file, the earliest dated transaction from the on-line financial statement is compared to the earliest dated transaction from the user's file, in step 706 . Next, in step 708 , a determination is made as to whether the earliest dated transaction from the user's file is later than the earliest dated transaction from the on-line financial statement. If so, the “YES” branch is followed to the END step 722 ; otherwise, the “NO” branch is followed to step 710 .
In step 710 , the ending period of the on-line financial statement is located. Next, in step 712 , a determination is made as to whether there is a transaction date from the user's file that has the same date as the ending period of the on-line financial statement. If so, the “YES” branch is followed to step 714 ; otherwise, the “NO” branch is followed to step 713 . In step 714 , the user's file is searched backwards from the transaction date that is the same as the ending period of the on-line financial statement to the earliest dated transaction in the user's file. During the search, a determination is made, in step 716 , as to whether there are any downloaded transactions already in the user's file. Downloaded transactions are identified with a flag to distinguish them from other transactions. If so, the “YES” branch is followed to the END step 722 ; otherwise, the “NO” branch is followed to step 718 . In step 718 , a new opening balance is calculated for the user's file. The new opening balance is then displayed in the user's file in step 719 . Next, in step 720 , a prompt indicating that the opening balance has changed is displayed. The process terminates at the END step 722 .
If there is no transaction from the user's file that has the same date as the ending period of the on-line financial statement, in step 713 , a transaction date from the user's file that is closest to, but earlier than, the ending period of the on-line financial statement is located. Next, in step 715 , the user's file is searched backwards from the transaction date located in the previous step 713 to the earliest dated transaction in the user's file. During the search, a determination is made, in step 716 , as to whether there are any downloaded transactions already in the user's file. If so, the “YES” branch is followed to the END step 722 ; otherwise, the “NO” branch is followed to step 718 . In step 718 , a new opening balance is calculated for the user's file. The new opening balance is then displayed in the user's file in step 719 . Next, in step 720 , a prompt is displayed indicating that the opening balance has changed. The process terminates at the END step 722 .
In summary, the ABA feature automatically reconciles an ending balance derived from a user's file or personal data store with an ending balance derived from an on-line banking service before downloading data from the on-line banking service by correcting the opening balance of the user's file.
Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its spirit and scope. Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description. | Payee names in received financial statements can be substituted for the benefit of users. The financial statements can be electronically received from a financial services provider. The financial statements typically comprise transaction entries that comprise an original payee name. A user can indicate a preferred name for the original payee name. If a match exists between an original name and a preferred name, the preferred name can be substituted for the original payee name. If a match does not exist, an active payee table can be used to display an original payee name. | 8 |
This application claims the benefit of Provisional Application 60/136,706 filed May 28, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is training devices used with putters to train golfers to putt properly.
2. Description of the Prior Art
Putting is a very important part of the game of golf. On a standard par 72 course, half of the allotted strokes toward par are allocated for putting. There are at least two important aspects in learning to be a good putter, these include proper alignment of the putter blade with respect to the target, and proper alignment of the golfer's eyes with respect to the ball. The importance of proper alignment of the putter blade with respect to the target is self evident since the object of putting is to accurately control the trajectory of the ball. The importance of eye position is that without ones eyes directly over the ball, the golfer cannot properly determine and learn the correct relationship between the putter face and the target. The importance of proper eye position in putting was pointed out by Jack Nicholas in his book, Golf My Way.
The importance of correct eye position has been pointed out in several U. S. Patents, which attempt to address the problem by various alignment devices involving lines and reflective surfaces. Examples of these devices include U.S. Pat. No. 4,601,472, which is a device that mounts on a putter head with an eye aligning mirror and a target aligning mirror, and U.S. Pat. No. 5,913,732 which involves stringing a target line to the hole and sighting the ball through the line. Other systems include aligning indicia which are a permanent part of the club.
Another device disclosed in U.S. Pat. No. 5,624,327 uses a flat plate which sits on the ground with a depression to hold a golf ball and a head position indicator behind the ball which is only visible when the user's head is in the right position and which changes color when the user moves his head.
Various laser devices have been disclosed. Some of these, such as U.S. Pat. No. 5,029,868, involve a laser generator which is part of the club itself. In that patent, a laser device is contained in the grip portion of the club where beams are conveyed by optical fibers to the putter and emitted from the face towards a target of side-by-side parallel reflective strips. Other devices such as U.S. Pat. No. 5,709,609 discloses various means of removably mounting various laser pointing devices in golf club heads.
The laser devices are an important contribution to putter training. The laser devices can only be used, however, in practice and a not during regulation play. It is thus important that a training device be removable, so that players can use it to train on their regulation putters. It is likewise important that the learning take place while the golfer's eyes are vertically aligned over the ball.
Another problem in learning to putt is that greens are not typically flat. Many are sloped such that one often needs to aim the putter blade at a point which is to the left or right of the hole. It is important that a training system be able to provide feedback, regarding the relationship between where the putt is directed and where the ball travels and comes to rest. It is important that this feedback be learned from well aligned putts.
There is a need for a putter training device that can be removably mountable on regulation putters which concurrently provides the user with a means to align the putter blade at a specific target location while the golf ball is in position and with a means to assure that the golfer's eyes are properly positioned vertically over the ball.
There is a need for a system and method for a golfer to learn the relationship between properly aligned putter face, the target and the path of the ball.
There is a need for a system and method for a learning golfer to systematically vary the direction in which the ball is targeted while maintaining proper eye position and putter face alignment.
SUMMARY OF THE INVENTION
An object of my invention is to provide a putter training device which can be removably attached to a putter and will be useful in training a golfer to align the putter blade with respect to a target while a golf ball is in place, and concurrently to align the eyes directly over the ball so as to observe the correct relationship between the putter blade, the ball, and the target.
A further object of my invention is to provide a visible laser beam originating just above the golf ball which displays a straight path along a plane normal to the putter surface and on target.
A still further object of my invention is to provide a calibrated target strip on which the laser beam is visible to the golfer.
A still further object of my invention is to provide a method for using the device and the calibrated target strip to learn the relationship between the direction at which the ball is targeted and a real or simulated golf hole.
A still further object of my invention is to provide a method for using the device and the target to evaluate the path of the putting stroke by observing the movement of the laser beam on the target, with respect to calibration lines.
My invention is an apparatus for practicing the art of golf putting. In one embodiment of the invention the apparatus includes an alignment device which can be removably mounted on a putter. The device has an enclosure that contains a laser emitting unit which produces a laser beam which passes out of the enclosure through a first aperture. The enclosure is mounted on the putter directly over the putter blade's “sweet spot” so that the laser beam follows a path which is in a plane normal to the striking surface of the putter blade. In a preferred embodiment, the enclosure also has a lens which converts the laser beam into a line beam. The enclosure also contains a light source and a second aperture which are located within the enclosure so that the light source and the second aperture fall on a vertical line when the enclosure is mounted on the golf club with the laser beam directed in a plane normal to the striking surface of the putter. The opening in the aperture is smaller than the diameter of the light source, which is preferably a light emitting diode. The enclosure is mounted on the golf club just above the blade and behind the striking surface, with the laser beam directed on a plane normal to the striking face and the second aperture directed upward. The golfer's eyes are aligned properly when the intensity of the image viewed through the second aperture is maximized. The combination of the laser beam and the light source provide a means for concurrently aligning the putter blade with a target while properly viewing the putter blade, the ball, and the target with the eyes vertically aligned with the putter blade striking surface.
The apparatus also includes a calibrated linear target strip with vertical calibration lines. The calibrated strip can be used on a golf course green or indoors or on another surface. When used on a green, the calibration strip is oriented to the left or right of the hole depending on the slope, with the origin of the target centered over the hole. The laser line beam is visible to the golfer on the target. When practicing, a golfer can align the beam with different offsets from the hole and iterate at different offsets until the desired performance is obtained. The golfer can also observe whether the putter blade is moving properly along the target line by observing the movement of the laser line on the target. On a flat surface, the putter blade is properly soled when the laser line is vertical (parallel to the calibration lines). The putting stroke is properly aligned along the target line when the laser line indicates no horizontal movement along the target.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying drawings, where:
FIG. 1 is a cutaway perspective view of the alignment device showing the internal components.
FIG. 2 is a perspective view of the alignment device mounted on a putter blade with a ball in place.
FIG. 3 is the target strip.
DESCRIPTION
FIG. 1 shows a perspective view of the alignment device showing the enclosure 10 , the first aperture 12 , the second aperture 14 , the laser unit 16 and the light source 18 , a light emitting diode (LED). A lens 20 is shown between the laser unit and the first aperture. The light emitting diode is shown mounted within the enclosure between a vertical guide surface 34 and the inner wall of the enclosure. A beam of light 36 is shown emanating from the laser unit and converted into a line of light by the lens between light rays 38 . A vertical beam of light 40 is shown emanating from the LED.
Also shown within the enclosure are a battery voltage source 24 , an on-off switch 22 , and wires connecting the light source and laser unit through the switch. The enclosure is mounted to a golf club by a bracket including a vertical surface 32 which fits in front of the striking surface and an opposing screw which is threaded through a threaded attachment 28 to the enclosure and operated by a thumb wheel 26 .
The other side of the enclosure is a mirror image of the side shown, without additional internals.
FIG. 2 shows the device mounted on the blade 42 of a putter between vertical surfaces 32 and the screw operated by thumb wheel 26 . The vertical surfaces 32 are shown attached to the enclosure by bracket 47 .
The laser line depicted by rays 38 emanate on a plane normal to the putter blade striking surface 44 . The vertical ray 40 emanating from aperture on the top of the device is above and behind the striking surface 44 , and the golf ball 46 .
FIG. 3 shows the left half of the calibrated target strip 50 . The strip has a number of vertical calibration lines 54 which show the distance from the outside edge of the hole 52 . Line 58 depicts a laser line from a properly soled and executed putting stroke, and line 56 depicts the laser line from an improper stroke where the putter was not soled properly. A putter is properly soled when while addressing the ball, the bottom of the putter head rests on the ground as it was designed to rest.
My invention is an apparatus for practicing the art of golf putting. In a preferred embodiment of the invention the apparatus includes an alignment device which can be removably mounted on a putter by hand. The device has an enclosure which contains a laser emitting unit which produces a laser beam which passes out of the enclosure through a first aperture. The enclosure is mounted on the putter directly over the putter blade “sweet spot” so that the laser beam follows a path which is in a plane normal to the striking surface of the putter blade. The enclosure also contains a light source and a second aperture which are located within the enclosure so that the light source and the second aperture fall on a vertical line when the enclosure is mounted on the golf club with the laser beam directed in a plane normal to the striking surface of the putter. In a preferred embodiment, the opening in the aperture is smaller than the diameter of the light source, which is preferably a light emitting diode. When the enclosure is mounted on the golf club just above blade and behind the striking surface with the laser beam directed on a plane normal to the striking face and the second aperture directed upward, the golfer's eyes are aligned properly when the intensity of the image viewed through the second aperture is maximized. The combination of the laser beam and the light source provide a means for concurrently aligning the putter blade with a target while properly viewing the putter blade, the ball, and the target with the eyes vertically aligned with the putter blade striking surface.
The laser emitting unit is preferably a small consumer laser such as are commonly used in laser pointers. A preferable laser emitting device is a class III laser. The laser is located to direct its laser beam through a first aperture on the side of the enclosure. The enclosure is mounted on the head of a putting club just above the striking surface which is usually substantially planar and is designed to sit in a substantially vertical position when the ball is struck. The striking surface of a putter generally has a “sweet spot” usually near the center of the blade, which is the desired location on the striking face to strike the ball. There are generally markings on the putter head to indicate the position of the sweet spot. The laser unit is mounted within the enclosure and the enclosure is mounted on the golf club head so that the laser beam is directed just above the sweet spot marking in the plane perpendicular to the striking surface at the sweet spot of the putter. The laser beam is preferably directed on a line on the perpendicular plane which is nearly perpendicular to the striking surface. The reason for this will become apparent below, because the apparatus can be used advantageously with a target strip which is placed on the golf course near the hole at which the putt is directed, and if so used it is important that the beam be visible on the target strip.
In a preferred embodiment of the invention, a lens or sequence of lenses is located between the laser unit and the first aperture which converts the laser beam into a laser line. The lens may be physically separate from the laser unit or it may be incorporated within a single container package often known as a laser line generator. A lens which is suitable to convert a laser beam into a line beam is a cylindrical lens, although other multiple element lenses are also acceptable. Lenses of this type are often described by their fan angle, which describes the angle of the arc enclosing the line as emitted from the lens. Fan angles from about 4° to 90° are readily available. The fan angle will determine the length of the line as it appears at the target, as well as the intensity of the line. The higher the angle the longer the line will be and, for a given powered laser, the lower will be the intensity of the line. In general, it is preferable to use a smaller fan angle and have a more intense line visible at the target strip. The relationship between distance and line size is shown in the table below for 4° and 45° fan angle lenses.
TABLE
Relationship between line height and distance as a function of
fan angle
Fan Angle
4°
45°
Line height at 5 ft.
0.35 ft.
4.14 ft.
Line height at 10 ft.
0.70 ft.
8.28 ft.
Line height at 25 ft.
1.75 ft.
20.70 ft.
The fan angle determines the maximum preferred amount that the laser beam can be inclined with respect to a horizontal line perpendicular to the striking face. In a preferred embodiment of the invention, the laser beam should be visible on a target strip set at distances between about 5 feet and about 25 feet from the putter.
The laser means can be a laser emitting unit described above, which could be an ordinary laser, a laser diode device, or an intense light beam of another sort which emits an intense light beam such as a laser device.
There are several preferred arrangements for the vertical alignment means for aligning the eyes vertically over the putter striking face. The first embodiment is a small light disposed within the enclosure so as to be on a vertical line with a second aperture located in the top of the enclosure when the apparatus is mounted on a putter head with the laser beam directed on a line in the plane perpendicular to the putter striking surface. Ideally, the second aperture will fall as close as possible to being over the striking surface of the putter. The second aperture should be smaller than the diameter of the light, preferably with an opening about half the size of the diameter of the light or less. A light emitting diode (LED) is a preferred light source. When viewed from above by a golfer, the LED is only visible when the golfer's eyes are in close proximity to a vertical line above the top hole. Also, as the golfer moves his head on an arc from one side of vertical through vertical to the other side, there is an identifiable optical response where the light is fully visible and of maximum intensity when viewed by the golfer along the vertical line from the top aperture. The response can be made clearer by including a vertical guide which confines the light to a relatively narrow column within the enclosure between the light source and the aperture.
The appearance can be varied by adjusting the relative size of the light source compared to the aperture and the distance that the light source is displaced below the aperture. A preferred set of dimensions is a ⅛ inch LED located ¾ inch below a {fraction (3/64)} inch diameter aperture, within an enclosure which is about 1.25 inches×1.25 inches×0.5 inches, though many equivalent sets of dimensions are possible.
An alternative embodiment includes the use of a convex LED. In a convex LED, the light output is already focused along a single line, so the positioning within the enclosure and the relative size of the light source and the aperture are less critical.
A preferred mounting means as shown in the figures comprises a pair of vertical brackets attached to the outside of the enclosure and an opposing thumb screw. The mounting device must securely attach the apparatus to the putter head over the sweet spot, with the laser beam directed on the plane substantially perpendicular to the striking face of the putter. Many alternatives will be obvious to those skilled in the art, such as brackets attached to the enclosure and fitting on the striking surface of the putter and the back opposing surface and tightening screws for securing the brackets between the surfaces. Other illustrative mounting means include bonding surfaces such as adhesive or Velcro type bonding to bond the enclosure to the top surface of the putter head or to bond a surface attached to the enclosure to a surface of the putter head. The apparatus may also be attached to the shaft of the putter and held out over the head by a support member. It is preferred that the mounting be such that the apparatus is readily removable from the putter so that a golfer can use the putter to practice with the apparatus in place or for regulation golf play with the apparatus removed. It is preferred that the mounting device not require distinctive drilling or other permanent modification of the putter. The mounting device preferably does not require tools or a complicated installation. Many variations will be obvious to those skilled in the art for removably mounting the apparatus so that the laser beam is directed along a line on a plane perpendicular to the striking face and the vertical aligning means is directed upwards.
The enclosure can be made of any appropriate light weight material such as high-strength plastic or aluminum. The enclosure can be readily made in two pieces which are attached together after the components are put inside. The enclosure preferably has support surfaces to hold the components in place. The components are attached to the enclosure by a method appropriate to the materials, such as soldering or gluing with an adhesive. An aluminum enclosure can be cast or stamped from sheet. A plastic enclosure can be molded or stamped.
In addition to the principal components as described above it will be obvious to those skilled in the art that auxiliaries are also required to operate the unit:
1. a voltage source, such as batteries to power the laser unit and the light source;
2. a switch to operate the laser and light source; and
3. appropriate electrical connections such as wiring and fasteners, all of which will be obvious to those skilled in the art.
A preferred embodiment of the invention includes a calibrated target strip shown in FIG. 3 . The target strip is preferably a strip with a linear scale showing distance from the outside edge of the hole. A preferred target is about 4 inches high and 36 inches long having a sequence of vertical lines spaced one inch apart. The target may also be reversible, with calibration lines on both sides of the target, to permit practice with left breaking or right breaking putts. A preferred target is self-supported by legs and positioned just behind the target hole. The strip is preferably enclosed in a clear plastic laminate for strength and protection.
The target plays an important part in using the apparatus. A golf green is often not a flat surface, and the proper strategy for reaching a hole is to aim the ball at a position which is displaced from the hole. The combination of the alignment device and the target allow the golfer to systematically choose different target positions and ball speeds and learn how to judge the break in a putt, while properly viewing the ball from a correct vertically aligned eye position.
A preferred method for using the apparatus includes the acts of:
1. Mounting a device on a putter having a substantially planar striking face, which produces:
a) a laser beam in a plane normal to the striking face of the putter just above the sweet spot, and
b) produces an identifiable optical response when the putter head is viewed from a correct vertically aligned view substantially directly above the striking face.
2. Positioning a calibrated target strip having a series of vertical distance lines directly over or behind a target hole on the golf course.
3. Directing the laser beam towards a position on the target, while viewing the putter striking surface from a position vertically above the sweet spot such that the identifiable response is observed.
4. Striking a golf ball positioned in front of the striking head and allowing it to roll to a resting place.
5. Observing the path of the ball and the resting place relative to the hole.
6. If the ball did not go into the hole or reach the position of the hole on the target repeat steps 3 through 5.
Another way to use the target apparatus is to place it on a level surface and view the pattern drawn by the laser beam on the target. If the putter is properly soled and the path of the club is maintained such that the putter head striking surface is directed down the target line during the stroke, the line drawn on the target will be vertical and therefore parallel to the calibration lines on the target (assuming that the target is located perpendicular to the target line). If the putter head is not properly soled, or is rotated or deviates from the target line during the stroke, the line drawn by the laser will not be vertical during address and furthermore will appear to move horizontally across one or more of the calibration lines.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof other versions are possible. Therefore the spirit and scope of the appended claims should not be limited to the preferred versions herein. | An apparatus and method for teaching golfers proper putting fundementals. The apparatus comprises a device which removably mounts over a putter head, projecting a laser beam on the plane perpendicular to the striking face of a putter just over the sweet spot. The apparatus also includes a means for the golfer to properly align the eyes vertically above the striking face. The laser beam is directed towards and on a linearly calibrated target strip. By directing a shot at various positions on the target strip while viewing the putter from a proper vertically aligned position, a golfer is able to learn to judge putting situations. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a method for improving the selectivity of supported silver catalysts for the production of ethylene oxide. Specifically, the invention relates to an improvement in the known process for incorporating promoters into such catalysts.
Supported silver-based catalysts have been used industrially for many years for the oxidation of ethylene to ethylene oxide with oxygen or air. Most of the ethylene which is reacted is converted into ethylene oxide on the silver-impregnated catalyst support material and the remainder of the ethylene is converted almost exclusively to carbon dioxide and water. The goal is to react as much ethylene as possible, i.e., high productivity, such that the greater amount of the ethylene is converted to ethylene oxide, i.e., high selectivity.
It is well-known in the art that the incorporation of promoters, such as rubidium or cesium, into these catalysts will increase the selectivity thereof. U.S. Pat. No. 4,012,425, issued Mar. 15, 1977, discloses one such process which comprises treating the catalyst with a solution of cesium or rubidium. There are many similar disclosures in the art, both for the manufacture of new catalyst and for the regeneration of spent catalyst. However, nowhere in the prior art is there any disclosure that any particular anion should be used with the promoters, other than that the anion should not be a catalyst poison such as sulfur-containing compounds. The above patent states that no unusual effectiveness is observed with the use of any particular anion and goes on to say that nitrates, nitrites, chlorides, iodides, bromates, bicarbonates, oxalates, acetates, tartrates, lactates, and isopropoxides may be used.
SUMMARY OF THE INVENTION
The present invention relates to an improvement in the known method for improving the selectivity of supported silver catalysts by incorporating a promoter therein. The improvement comprises forming a solution of a compound of the promoter and an anion selected from the group consisting of unsaturated carboxylic acids, aminoorganic acids, and hydroxybenzoic acids in the solvent and then contacting the catalyst with the solution. The solution is drained from the catalyst and the catalyst is dried.
DETAILED DESCRIPTION OF THE INVENTION
The addition of promoters to silver-based ethylene oxide catalysts is an established part of the art of catalyst manufacture. Promoters have been added to both new and used catalysts to provide increased selectivity and activity. A large array of anions have been listed as suitable for use with promoters. The chief restriction on the anion is the lack of harmful effect on catalyst performance.
It has been found that certain promoter-anion combinations are superior to those routinely employed in catalyst manufacture or regeneration today. The anion employed must have two general characterstics: (1) formation of a compound with a promoter which is soluble in a suitable solvent and (2) it must have one or more functional groups which have an affinity for the promoter ion and one or more groups which have an affinity for the silver surface of the catalyst. The solubility of the promoter-anion combination is not restricted to water or aqueous systems, but encompasses all non-aqueous solvents that of themselves or in combination are not deleterious to catalyst performance. Suitable solvents are methanol, water, aliphatic, alicyclic, or aromatic ethers, alcohols, hydrocarbons, and ketones, and aliphatic or aromatic esters, amines, amides, aldehydes, and nitriles.
The polyfunctionality of the anion provides for site specific application of the promoter, optimum promoter utilization, and superior catalyst performance. The method provides homogeneous application of the promoter to the catalyst and minimizes the macro and microscopic concentration variations which adversely effect catalyst performance. The homogeneity is provided by the affinity of the functional groups for the silver surface of the catalyst. For the purpose of this invention, the anion preferably should not be solely of a chelating type in which all of the functional groups are tied up by the promoter cation. One or more of the functional groups should remain relatively free for complexation with the silver surface.
The anions which provide the above advantages and which are claimed herein are those derived from unsaturated carboxylic acids, aminoorganic acids, and hydroxybenzoic acids. Examples of suitable unsaturated carboxylic acids are acrylic acid, vinylacetic acid, and 5-hexenoic acid. Examples of suitable aminoorganic acids are m-aminobenzoic acid, p-aminobenzoic acid, alpha-aminobutyric acid, and 6-aminocaproic acid. Examples of the hydroxybenzoic acids are m-hydroxybenzoic acid and p-hydroxybenzoic acid.
The method by which the above advantages are achieved comprises forming a compound of the promoter ion which is to be incorporated into the catalyst and one of the above anions, forming a solution of said compound in a suitable solvent, and then contacting the catalyst with the solution. The concentration of promoter in this solution should be in the range of 1 to 10,000 parts per million. This method can be used in the production of new catalyst by simply applying the above solution at the end of the normal catalyst manufacturing process. The method can be used in the regeneration of used catalyst by merely contacting the used catalyst with the solution.
EXAMPLE
A single sample of aged silver-based ethylene oxide catalyst was used in all of the following experiments. The sample was split into several 60-gram portions for identical treatment with cesium salts of the different anions. The treatment procedure consisted of contacting the catalyst sample with 70 milliliters of a 100 part per million cesium in methanol solution for two hours, draining, and then drying at 60° C. for 20 hours. The 100 parts per million cesium solution was prepared by mixing a 100 parts per million cesium hydroxide solution with an equivalent quantity of the acid according to the equation
CsOH+HOA→CsOA+H.sub.2 O
where OA represent the anion of the acid.
For this evaluation, acetate provided the base line for a monofunctional anion. The dried treated catalysts were evaluated by manufacturing ethylene oxide in a reactor at a temperature of 400°-500° F. at a flow rate of 200 milliliters per minute of inlet gas with a composition of 7 percent oxygen, 8 percent carbon dioxide, 18 percent ethylene, and nitrogen ballast with 1 part per million of ethylene dichloride added as an inhibitor.
The results of these experiments, shown in the following table, prove that the catalysts which were treated with the polyfunctional anions were superior catalysts to the catalyst which was treated with the monofunctional acetate ion.
TABLE 1______________________________________ % Selec- tivity at 1.5% Temp.Acid Anion Δ EO* °F.______________________________________Acetic Acetate 70.4 452Acrylic Acrylate 72.0 447m-Aminobenzoic m-Aminobenzoate 72.6 458p-Aminobenzoic p-Aminobenzoate 74.0 443gamma-Aminobutyric gamma-Aminobutyrate 72.5 4396-Aminocaproic 6-Aminocaproate 70.8 480m-Hydroxybenzoic m-Hydroxybenzoate 71.9 451p-Hydroxybenzoic p-Hydroxybenzoate 72.8 476______________________________________ *The term Selectivity at 1.5% Δ EO means the selectivity at a productivity of 1.5%. | An improved method is disclosed for improving the selectivity of supported silver catalysts by incorporating a promoter therein. The improvement comprises forming a solution of a compound of the promoter and an anion selected from the group consisting of unsaturated carboxylic acids, aminoorganic acids, and hydroxybenzoic acids in a solvent and contacting the catalyst with the solution. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a Continuation of U.S. patent application Ser. No. 11/747,203, filed May 10, 2007, which is a Continuation-in-Part of U.S. patent application Ser. No. 11/676,623 entitled “Creatine-Fatty Acids,” filed Feb. 20, 2007, now U.S. Pat. No. 7,314,945, and claims benefit of priority thereto; the disclosures of which are all hereby fully incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to structures and synthesis of amino acid-fatty acid compounds bound via an anhydride linkage. Specifically, the present invention relates to a compound comprising an amino acid bound to a fatty acid, wherein the fatty acid is preferably a saturated fatty acid and bound to the amino acid via an anhydride linkage.
BACKGROUND OF THE INVENTION
Participation in sports at any level either professional or amateur requires an athlete to strive to bring their bodies to a physical state which is considered optimum for the sport of interest. One of the factors that correlate positively with successful participation in a sport is a high degree of development of the aerobic capacity and/or strength of skeletal muscle. Consequently, it is important that nutrients and other requirements of muscles be readily available and that they be transported to areas where they are needed without obstructions.
Strength and aerobic capacity are both functions of training and of muscle mass. As such, an athlete who can train harder and longer is often considered to be the most effective at participation in the sport of interest. Strenuous exercise is an effective stimulus for protein synthesis. However, muscle requires a large array of nutrients, including amino acids, in order to facilitate this increased level of protein synthesis.
Following periods of strenuous exercise, muscle tissue enters a stage of rapid nitrogen absorption in the form of amino acids and small peptides. This state of increased nitrogen absorption is a result of the body repairing exercise-induced muscle fiber damage as well as the growth and formation of new muscle fibers. It is important that muscles have sufficient levels of nitrogen, in the form of amino acids and small peptides, during this period of repair and growth. When an athlete is participating in a strenuous exercise regime and fails to ingest enough nitrogen, e.g. amino acids, the body often enters a state of negative nitrogen balance. A negative nitrogen balance is a state in which the body requires more nitrogen, to facilitate repair and growth of muscle, than is being ingested. This state causes the body to catabolize muscle in order to obtain the nitrogen required, and thus results in a decrease in muscle mass and/or attenuation of exercise-induced muscle growth. Therefore, it is important that athletes ingest adequate amounts of amino acids in order to minimize the catabolism of muscle in order to obtain the results desired from training.
Although supplementation with amino acids are quite common, the uptake of amino acids by cells is limited or slow since amino acid residues are not soluble or only slightly soluble in nonpolar organic solution, such as the lipid bilayer of cells. As a result amino acids must be transported into cells via transport mechanisms which are specific to the charges that the amino acid bears. It is therefore desirable to provide, for use in individuals, e.g. animals and humans, forms and derivatives of amino acids with improved characteristics that result in increased stability and increased uptake by cells. Furthermore, it would be advantageous to do so in a manner that provides additional functionality as compared to amino acids alone.
Fatty acids are carboxylic acids, often containing a long, unbranched chain of carbon atoms and are either saturated or unsaturated. Saturated fatty acids do not contain double bonds or other functional groups, but contain the maximum number of hydrogen atoms, with the exception of the carboxylic acid group. In contrast, unsaturated fatty acids contain one or more double bonds between adjacent carbon atoms, of the chains, in cis or trans configuration
The human body can produce all but two of the fatty acids it requires, thus, essential fatty acids are fatty acids that must be obtained from food sources due to an inability of the body to synthesize them, yet are required for normal biological function. The fatty acids which are essential to humans are linoleic acid and α-linolenic acid.
Examples of saturated fatty acids include, but are not limited to myristic or tetradecanoic acid, palmitic or hexadecanoic acid, stearic or octadecanoic acid, arachidic or eicosanoic acid, behenic or docosanoic acid, butyric or butanoic acid, caproic or hexanoic acid, caprylic or octanoic acid, capric or decanoic acid, and lauric or dodecanoic acid, wherein the aforementioned comprise from at least 4 carbons to 22 carbons in the chain.
Examples of unsaturated fatty acids include, but are not limited to oleic acid, linoleic acid, linolenic acid, arachidonic acid, palmitoleic acid, eicosapentaenoic acid, docosahexaenoic acid and erucic acid, wherein the aforementioned comprise from at least 4 carbons to 22 carbons in the chain.
Fatty acids are capable of undergoing chemical reactions common to carboxylic acids. Of particular relevance to the present invention are the formation of anhydrides and the formation of esters.
SUMMARY OF THE INVENTION
In the present invention, compounds are disclosed, where the compounds comprise an amino acid bound to a fatty acid, via an anhydride linkage, and having a structure of Formula 1:
where:
R 1 is an alkyl group, preferably saturated, and containing from about 3 to a maximum of 21 carbons. R 2 is hydrogen, methyl, isopropyl, isobutyl, sec butyl, acetylamide, propylamide, butyl-1-amine, or 1-butylguanidine.
Another aspect of the invention comprises the use of a saturated fatty acid in the production of compounds disclosed herein.
A further aspect of the present invention comprises the use of an unsaturated fatty in the production of compounds disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these specific details.
The present invention relates to structures and synthesis of amino acid-fatty acid compounds bound via an anhydride linkage. In addition, specific benefits are conferred by the particular fatty acid used to form the compounds in addition to, and separate from, the amino acid substituent.
As used herein, the term ‘fatty acid’ includes both saturated, i.e. an alkane chain as known in the art, having no double bonds between carbons of the chain and having the maximum number of hydrogen atoms, and unsaturated, i.e. an alkene or alkyne chain, having at least one double or alternatively triple bond between carbons of the chain, respectively, and further terminating the chain in a carboxylic acid as is commonly known in the art, wherein the hydrocarbon chain is greater than four carbon atoms. Furthermore, essential fatty acids are herein understood to be included by the term ‘fatty acid’.
As used herein, “amino acid” refers a compound consisting of a carbon atom to which are attached a primary amino group, a carboxylic acid group, a side chain, and a hydrogen atom. For example, the term “amino acid” includes, but is not limited to, Glycine, Alanine, Valine, Leucine, Isoleucine, Asparagine, Glutamine, Lysine and Arginine. Additionally, as used herein, “amino acid” also includes derivatives of amino acids such as esters, and amides, and salts, as well as other derivatives, including derivatives having pharmacoproperties upon metabolism to an active form.
According to the present invention, the compounds disclosed herein comprise an amino acid bound to a fatty acid, wherein the fatty acid is preferably a saturated fatty acid. Furthermore, the amino acid and fatty acid are bound via an anhydride linkage and having a structure according to that of Formula 1. The aforementioned compound being prepared according to the reaction as set forth for the purposes of the description in Scheme 1:
With reference to Scheme 1, in Step 1 an acyl halide (4) is produced via reaction of a fatty acid (2) with a thionyl halide (3).
In various embodiments of the present invention, the fatty acid of (2) is selected from the saturated fatty acid group comprising butyric or butanoic acid, caproic or hexanoic acid, caprylic or octanoic acid, capric or decanoic acid, lauric or dodecanoic acid, myristic or tetradecanoic acid, palmitic or hexadecanoic acid, stearic or octadecanoic acid, arachidic or eicosanoic acid, and behenic or docosanoic acid.
In alternative embodiments, of the present invention, the fatty acid of (2) is selected from the unsaturated fatty acid group comprising oleic acid, linoleic acid, linolenic acid, arachidonic acid, palmitoleic acid, eicosapentaenoic acid, docosahexaenoic acid, and erucic acid.
Furthermore, the thionyl halide of (3) is selected from the group consisting of fluorine, chlorine, bromine, and iodine, the preferred method using chlorine or bromine.
The above reaction proceeds under conditions of heat ranging between from about 35° C. to about 50° C. and stirring over a period from about 0.5 hours to about 2 hours during which time the gases sulfur dioxide and acidic gas, wherein the acidic gas species is dependent on the species of thionyl halide employed, are evolved. Preferably, the reaction proceeds at 45° C. for 1.5 hours.
Step 2 of Scheme 1 entails the neutralization of the carboxylic acid of the amino acid portion through the addition of an inorganic base. The inorganic base is selected from the group comprising sodium hydroxide, potassium hydroxide, lithium hydroxide, ammonium hydroxide, sodium carbonate. Preferred inorganic bases for the purposes of the present invention are sodium hydroxide and potassium hydroxide.
Neutralization, as described above, is followed by the evaporation of water, resulting in the isolation of the corresponding salt. For example, using the amino acid, Arginine and the inorganic base potassium hydroxide, results in the production of the potassium Arginine salt.
Step 3 of Scheme 1 involves the drop wise addition of the prepared acyl halide (4) to the amino acid salt (6) in a cooled flask and subsequent purification by two rounds of distillation to yield the desired anhydride compound (1), the anhydride compound being an amino acid-fatty acid compound of the present invention.
In various embodiments, according to the aforementioned, using the saturated fatty acids, a number of compounds are produced; examples include, but are not limited to: 2-amino-3-methylbutanoic butyric anhydride, 2-amino-3-methylpentanoic hexanoic anhydride, 2,4-diamino-4-oxobutanoic octanoic anhydride, 2,4-diamino-4-oxobutanoic decanoic anhydride, 2-amino-5-guanidinopentanoic dodecanoic anhydride, 2,6-diaminohexanoic tetradecanoic anhydride, 2-amino-5-guanidinopentanoic palmitic anhydride, 2-amino-4-methylpentanoic stearic anhydride, 2-aminopropanoic icosanoic anhydride, and 2-aminoacetic docosanoic anhydride.
In additional embodiments, according to the aforementioned, using the unsaturated fatty acids, a number of compounds are produced; examples include, but are not limited to: 2-aminopropanoic (7Z,10Z)-hexadeca-7,10-dienoic anhydride, 2,5-diamino-5-oxopentanoic oleic anhydride, 2,4-diamino-4-oxobutanoic (9Z,12Z,15Z)-octadeca-9,12,15-trienoic anhydride, 2-aminoacetic (5Z,8Z,11Z,14Z)-icosa-5,8,11,14-tetraenoic anhydride, 2-amino-5-guanidinopentanoic (Z)-hexadex-9-enoic anhydride, 2-amino-3-methylpentanoic (5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenoic anhydride, 2-amino-4-methylpentanoic (4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexenoic anhydride, and 2-amino-3-methylbutanoic (Z)-docos-13-enoic anhydride.
The following examples illustrate specific amino acid-fatty acid anhydrides and routes of synthesis thereof. One of skill in the art may envision various other combinations within the scope of the present invention, considering examples with reference to the specification herein provided.
EXAMPLE 1
2-amino-3-methylbutanoic butyric anhydride
In a dry 2-necked, round bottomed flask, equipped with a magnetic stirrer and fixed with a separatory funnel, containing 8.75 ml (120 mmol) of thionyl chloride, and a water condenser, is placed 9.05 ml (100 mmol) of butanoic acid. Addition of the thionyl chloride is completed with heating to about 40° C. over the course of about 30 minutes. When addition of the thionyl chloride is complete the mixture is heated and stirred for an additional 30 minutes. The water condenser is then replaced with a distillation side arm condenser and the crude mixture is distilled. The crude distillate in the receiving flask is then fractionally distilled to obtain the acyl chloride, butyryl chloride.
Separately, in a single-necked, round bottomed flask, equipped with a magnetic stirrer, 5.86 g (50 mmol) of Valine is dissolved in 200 ml of water. To this is added 55 ml of 1M sodium hydroxide with vigorous stirring, until heat production ceases. At this point the water is removed by evaporation to yield the carboxylate salt, sodium 2-amino-3-methylbutanoate, shown below.
Finally, in a dry 2-necked, round bottomed flask, fixed with a separatory funnel, containing 6.39 g (60 mmol) of the prepared butyryl chloride, and side arm water condenser fixed with a dry receiving flask, is placed 9.18 g (66 mmol) of sodium 2-amino-3-methylbutanoate. The round bottomed flask is placed in an ice bath and the butyryl chloride is added drop wise. After addition is completed the mixture is shaken and the ice bath is replaced by a heating mantle. The flask is then heated until no more solution is dropping into the receiving flask. This crude distillate is then further fractionally distilled to yield 2-amino-3-methylbutanoic butyric anhydride.
EXAMPLE 2
2-amino-3-methylpentanoic hexanoic anhydride
In a dry 2-necked, round bottomed flask, equipped with a magnetic stirrer and fixed with a separatory funnel, containing 6.97 ml (90 mmol) of thionyl bromide, and a water condenser, is placed 5.68 ml (45 mmol) of hexanoic acid. Addition of the thionyl bromide is completed with heating to about 50° C. over the course of about 50 minutes. When addition of the thionyl bromide is complete the mixture is heated and stirred for an additional hour. The water condenser is then replaced with a distillation side arm condenser and the crude mixture is distilled. The crude distillate in the receiving flask is then fractionally distilled to obtain the acyl bromide, hexanoyl bromide.
Separately, in a single-necked, round bottomed flask, equipped with a magnetic stirrer, 6.56 g (50 mmol) of Isoleucine is dissolved in 200 ml of water. To this is added 55 ml of 1M sodium hydroxide with vigorous stirring, until heat production ceases. At this point the water is removed by evaporation to yield the carboxylate salt, sodium 2-amino-3-methylpentanoate, shown below.
Finally, in a dry 2-necked, round bottomed flask, fixed with a separatory funnel, containing 10.81 g (60 mmol) of the prepared hexanoyl bromide, and side arm water condenser fixed with a dry receiving flask, is placed 11.03 g (72 mmol) of sodium 2-amino-3-methylpentanoate. The round bottomed flask is placed in an ice bath and the hexanoyl bromide is added drop wise. After addition is completed the mixture is shaken and the ice bath is replaced by a heating mantle. The flask is then heated until no more solution is dropping into the receiving flask. This crude distillate is then further fractionally distilled to yield 2-amino-3-methylpentanoic hexanoic anhydride.
EXAMPLE 3
2-amino-5-guanidinopentanoic dodecanoic anhydride
In a dry 2-necked, round bottomed flask, equipped with a magnetic stirrer and fixed with a separatory funnel, containing 5.85 ml (80 mmol) of thionyl chloride, and a water condenser, is placed 10.02 g (50 mmol) of dodecanoic acid. Addition of the thionyl chloride is completed with heating to about 45° C. over the course of about 40 minutes. When addition of the thionyl chloride is complete the mixture is heated and stirred for an additional 50 minutes. The water condenser is then replaced with a distillation side arm condenser and the crude mixture is distilled. The crude distillate in the receiving flask is then fractionally distilled to obtain the acyl chloride, dodecanoyl chloride.
Separately, in a single-necked, round bottomed flask, equipped with a magnetic stirrer, 10.45 g (60 mmol) of Arginine is dissolved in 300 ml of water. To this is added 78 ml of 1M ammonium hydroxide with vigorous stirring, until heat production ceases. At this point the water is removed by evaporation to yield the carboxylate salt, ammonium 2-amino-5-guanidinopentanoate, shown below.
Finally, in a dry 2-necked, round bottomed flask, fixed with a separatory funnel, containing 15.31 g (70 mmol) of the prepared dodecanoyl chloride, and side arm water condenser fixed with a dry receiving flask, is placed 16.06 g (84 mmol) of ammonium 2-amino-5-guanidinopentanoate. The round bottomed flask is placed in an ice bath and the dodecanoyl chloride is added drop wise. After addition is completed the mixture is shaken and the ice bath is replaced by a heating mantle. The flask is then heated until no more solution is dropping into the receiving flask. This crude distillate is then further fractionally distilled to yield 2-amino-5-guanidinopentanoic dodecanoic anhydride.
EXAMPLE 4
2-amino-4-methylpentanoic stearic anhydride
In a dry 2-necked, round bottomed flask, equipped with a magnetic stirrer and fixed with a separatory funnel, containing 4.81 ml (66 mmol) of thionyl chloride, and a water condenser, is placed 15.65 g (55 mmol) of stearic acid. Addition of the thionyl chloride is completed with heating to about 45° C. over the course of about 40 minutes. When addition of the thionyl chloride is complete the mixture is heated and stirred for an additional 45 minutes. The water condenser is then replaced with a distillation side arm condenser and the crude mixture is distilled. The crude distillate in the receiving flask is then fractionally distilled to obtain the acyl chloride, stearoyl chloride.
Separately, in a single-necked, round bottomed flask, equipped with a magnetic stirrer, 7.87 g (60 mmol) of Leucine is dissolved in 300 ml of water. To this is added 72 ml of 1M potassium hydroxide with vigorous stirring, until heat production ceases. At this point the water is removed by evaporation to yield the carboxylate salt, potassium 2-amino-4-methylpentanoate, shown below.
Finally, in a dry 2-necked, round bottomed flask, fixed with a separatory funnel, containing 21.27 g (70 mmol) of the prepared stearoyl chloride, and side arm water condenser fixed with a dry receiving flask, is placed 13.03 g (77 mmol) of potassium 2-amino-4-methylpentanoate. The round bottomed flask is placed in an ice bath and the stearoyl chloride is added drop wise. After addition is completed the mixture is shaken and the ice bath is replaced by a heating mantle. The flask is then heated until no more solution is dropping into the receiving flask. This crude distillate is then further fractionally distilled to yield 2-amino-4-methylpentanoic stearic anhydride.
EXAMPLE 5
2-aminopropanoic (7Z,10Z)-hexadeca-7,10-dienoic anhydride
In a dry 2-necked, round bottomed flask, equipped with a magnetic stirrer and fixed with a separatory funnel, containing 9.35 ml (128 mmol) of thionyl chloride, and a water condenser, is placed 24.90 ml (80 mmol) of linoleic acid. Addition of the thionyl chloride is completed with heating to about 40° C. over the course of about 40 minutes. When addition of the thionyl chloride is complete the mixture is heated and stirred for an additional 50 minutes. The water condenser is then replaced with a distillation side arm condenser and the crude mixture is distilled. The crude distillate in the receiving flask is then fractionally distilled to obtain the acyl chloride, (9Z,12Z)-octadeca-9,12-dienoyl chloride.
Separately, in a single-necked, round bottomed flask, equipped with a magnetic stirrer, 5.34 g (60 mmol) of Alanine is dissolved in 200 ml of water. To this is added 78 ml of 1M ammonium hydroxide with vigorous stirring, until heat production ceases. At this point the water is removed by evaporation to yield the carboxylate salt, ammonium 2-aminopropanoate, shown below.
Finally, in a dry 2-necked, round bottomed flask, fixed with a separatory funnel, containing 17.93 g (60 mmol) of the prepared (9Z,12Z)-octadeca-9,12-dienoyl chloride, and side arm water condenser fixed with a dry receiving flask, is placed 7.64 g (72 mmol) of ammonium 2-aminopropanoate. The round bottomed flask is placed in an ice bath and the (9Z,12Z)-octadeca-9,12-dienoyl chloride is added drop wise. After addition is completed the mixture is shaken and the ice bath is replaced by a heating mantle. The flask is then heated until no more solution is dropping into the receiving flask. This crude distillate is then further fractionally distilled to yield 2-aminopropanoic (7Z,10Z)-hexadeca-7,10-dienoic anhydride.
Thus while not wishing to be bound by theory, it is understood that reacting an amino acid or derivative thereof with a fatty acid or derivative thereof to form an anhydride can be used enhance the bioavailability of the amino acid or derivative thereof by improving stability of the amino acid in terms of resistance to hydrolysis in the stomach and blood and by increasing solubility and absorption. Furthermore, it is understood that, dependent upon the specific fatty acid, for example, saturated fatty acids form straight chains allowing mammals to store chemical energy densely, or derivative thereof employed in the foregoing synthesis, additional fatty acid-specific benefits, separate from the amino acid substituent, will be conferred.
EXTENSIONS AND ALTERNATIVES
In the foregoing specification, the invention has been described with a specific embodiment thereof; however, it will be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. | The present invention describes compounds produced from an amino acid molecule and a fatty acid molecule. The compounds being in the form of amino-fatty acid compounds being bound by an anhydride linkage, or mixtures thereof made by reacting amino acids or derivatives thereof with an appropriate fatty acid previously reacted with a thionyl halide. The administration of such molecules provides supplemental amino acids with enhanced bioavailability and the additional benefits conferred by the specific fatty acid. | 2 |
RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No. 10/792,780, filed Mar. 5, 2004, which claims the benefit of U.S. provisional application No. 60/452,527, filed Mar. 7, 2003, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of surgery and, more particularly, to methods and apparatus for retrograde repair of osteochondral defects.
BACKGROUND OF THE INVENTION
[0003] Methods and apparatus related to arthroscopic osteochondral transplantation for repairing chondral defects are known in the art. For example, U.S. Pat. No. 5,919,196, the disclosure of which is incorporated by reference herein, involves autograft transplantation using matched graft harvesters and recipient site harvesters, in the form of tubes with collared pins, to create and transplant donor graft osteochondral cores into correspondingly sized recipient sockets.
[0004] Although the above-described procedure is a significant improvement over prior art techniques for osteochondral transplantation, it is difficult to access defects on the tibial plateau using donor and recipient harvesters, as required in the technique of the '196 patent.
[0005] Accordingly, it would be desirable to provide apparatus and methods for creating the recipient site socket from the inside out, i.e., using a retrograde technique. It would also be desirable to provide a technique for inserting the replacement osteochondral core or implant in a retrograde manner to obviate inserting a harvester into the joint.
SUMMARY OF THE INVENTION
[0006] The present invention overcomes the disadvantages of the prior art and fulfills the needs noted above by providing a retrograde osteochondral system by which a grafted healthy bone or synthetic implant is implanted into the recipient site in a retrograde manner.
[0007] The retrograde osteochondral system of the present invention employs a retrodrill device for osteochondral reconstruction. The retrodrill device is provided with a retrograde cutter that is detachable from a guide pin. The cutter has a cannulated body provided with a plurality of cutting flutes on a proximal face and disposed radially. The guide pin includes a cannulated body with a proximal end and a distal end, and a trocar disposed in the lumen of the cannulated body. The exterior of the cannulated body is provided with graduated depth markings. The cannulated body of the guide pin has threads toward the distal end for receiving corresponding threads in the cannulation of the retrodrill cutter.
[0008] According to one embodiment of the present invention, retrograde osteochondral reconstruction is conducted using the retrodrill cutter in a retrograde manner to form a recipient socket at the location of an osteochondral lesion developed on the head of the tibia, for example. Socket depth is gauged using by employing depth markings on the cannulated retrodrill guide pin. More specifically, formation of the recipient socket begins by using the retrodrill guide pin with the inserted trocar to drill a tunnel through an upper portion of the tibia, from behind and through the osteochondral lesion, and into the tibial joint space. A drill guide with a marking hook placed on the lesion is used to ensure accurate placement of the guide pin. The retrodrill cutter is then inserted into the joint space and oriented perpendicularly to the tibial lesion so that the guide pin can be inserted into, and threadingly engaged with, the retrodrill cutter. Once secured to the retrodrill cutter, the guide pin is retracted until the proximal cutting face of the retrodrill cutter contacts the tibial osteochondral lesion. The retrodrill cutter is then rotated and further retracted through the osteochondral lesion and into the tibia to the proper depth as measured on the outside of the knee by the depth markings on the guide pin. The retrodrill cutter is advanced out of the completed socket, and disengaged from the retrodrill guide pin by applying a reverse drilling motion to the guide pin while holding the cutter stationary.
[0009] A core, such as a graft bone core or a synthetic implant, is fitted with a length of suture to provide a means for pulling the core into the tibial recipient socket described above. The length of suture preferably passes through a longitudinal cannulation in the core, made available by removing the trocar, and is secured to the core using either a knot at the back end, an adhesive, insert molding, or equivalent securing methods. The suture extends through the leading tip of the core a sufficient length to allow the suture to pass through the cannulated retrodrill guide pin and be grasped for pulling the core into the tibial socket.
[0010] Other features and advantages of the present invention will become apparent from the following description of the invention, which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1A-1C illustrate a retrodrill cutter according to the present invention.
[0012] FIGS. 2A-2B illustrate a retrodrill guide pin including a cannulated body and a trocar according to the present invention.
[0013] FIG. 3 schematically illustrates the formation of a socket at a tibial recipient site according to the present invention.
[0014] FIG. 4 schematically illustrates the formation of a tibial recipient socket at a stage subsequent to that shown in FIG. 3 .
[0015] FIG. 5 schematically illustrates the formation of a tibial recipient socket at a stage subsequent to that shown in FIG. 4 .
[0016] FIG. 6 schematically illustrates the formation of a tibial recipient socket at a stage subsequent to that shown in FIG. 5 .
[0017] FIG. 7 schematically illustrates a completed socket formed at the tibial recipient site.
[0018] FIG. 8 schematically illustrates the installation of an osteochondral core within the tibial socket formed according to the present invention.
[0019] FIG. 9 schematically illustrates the installation of osteochondral core at a stage of processing subsequent to that shown in FIG. 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] The present invention provides a retrodrill technique and apparatus for providing a recipient bone site or socket that is formed in a retrograde manner during retrograde osteochondral repair. A core, such as a grafted healthy bone or a synthetic implant, is installed into the recipient bone socket in a retrograde manner.
[0021] Referring now to the drawings, where like elements are designated by like reference numerals, FIGS. 1-2 illustrate a retrodrill cutter 10 ( FIGS. 1A-1C ) which is adapted to be threadedly engaged by a retrodrill guide pin 50 ( FIGS. 2A and 2B ). The retrodrill cutter 10 is formed of a cannulated body 11 surrounded by a plurality of cutting flutes formed by longitudinal teeth 12 . Cannulation 13 has internal threads 14 , discussed further below.
[0022] The retrodrill guide pin 50 has a proximal end 54 , a distal end 52 , and a cannulated body 53 , which is lazed with calibrated depth markings 56 . The lumen of the cannulated body accepts a trocar 58 having a pointed tip 59 . When the trocar is removed, a strand of suture can be passed through the lumen of the cannulated body. The proximal end 54 of the cannulated body of retrodrill guide pin 50 is configured for chucking into a rotary driver (not shown) and includes a setscrew collar 62 for securing an axial position of the trocar 58 in the cannulated body 53 . The distal end 52 of the retrodrill guide pin 50 is open at the tip to expose the pointed end 59 of the trocar 58 . Distal end 52 also features a fluted region 51 and a threaded region 55 ( FIG. 2B ). Threaded region 55 is designed to engage corresponding threads 14 provided in the cannulation 13 of the retrodrill cutter 10 . Accordingly, the diameter of the cannula 13 of the retrodrill cutter 10 closely approximates the diameter of outer threaded region 55 of the retrodrill guide pin 50 , to allow engagement of the outer threaded region 55 with the inner threads 14 of retrodrill cutter 10 .
[0023] The threaded region 55 has an outer diameter that closely approximates, and preferably is less than, the diameter of shaft 53 . Threaded region 55 terminates proximally to meet a shoulder 57 established by the remaining portion of shaft 53 , the shoulder 57 providing a stop for the inner threads of cutter 10 . Threaded region 55 and fluted tip 51 partially overlap. A portion of the fluted tip extends distally beyond threaded region 55 , preferably substantially the length of the threaded cannula of the cutter. Accordingly, the cutter can be positioned conveniently over an unthreaded portion of the fluted tip as an initial step of assembling the cutter onto the guide pin.
[0024] A preferred method of forming a tibial socket using the retrodrill guide pin 50 and the retrodrill cutter 10 of the present invention, and then installing core 46 within the formed tibial socket, is described below with reference to FIGS. 3-9 .
[0025] FIG. 3 illustrates a schematic anterior view of a knee 60 in which osteochondral lesion or defect 69 is located on tibial plateau 63 of tibia 66 . Standard diagnostic arthroscopy is employed to evaluate the location and extent of the osteochondral lesion 69 , as well as the defect pathology. As described below, the osteochondral lesion 69 is drilled out by employing a retrodrill technique in connection with a retrograde osteochondral repair method of the present invention.
[0026] A long adapter drill guide 70 , for example an Arthrex C-Ring cross-pin drill guide such as those disclosed in U.S. Pat. Nos. 5,350,383 and 5,918,604, the disclosures of which are incorporated by reference herein, is secured to the lateral thigh, as shown in FIG. 3 . Marking hook 72 of the adapter drill guide 70 is inserted into the joint space near intercondylar notch 71 and positioned over the osteochondral lesion 69 of the tibial plateau 63 . Hook 72 includes a laser mark located anterior to tip 73 of the marking hook 72 , to ensure placement of a guide pin 50 at a ninety-degree retrograde entry relative to the osteochondral lesion 69 . The marking hook is held in position on the drill guide 70 by tightening knurled knob 75 .
[0027] Once the drill guide 70 is properly positioned, cannulated retrodrill guide pin 50 is placed through sleeve 78 of the drill guide 70 . Referring to FIG. 2A , trocar 58 is inserted in the cannulation of guide pin 50 and secured in place using setscrew collar 62 to provide the guide pin 50 with a pointed tip. As shown in FIG. 4 , the guide pin 50 is installed through the bone in an anterior-to-posterior direction relative to the osteochondral lesion 69 , forming a narrow (3 mm) tunnel 67 through the bone and perpendicular to the osteochondral lesion 69 . The cannulated retrodrill guide pin 50 is drilled through the lesion toward the tibial joint space until contact is made with the marking hook 72 of long adapter drill guide 70 .
[0028] Once the guide pin is drilled into the tibial space, the trocar 58 is removed, and a strand 43 is inserted in its place through the cannulated body and into the joint space. An end of the strand is placed through the cannulation of retrodrill cutter 10 and secured, and the retrodrill cutter 10 is drawn into the joint space and aligned perpendicularly with the tibial lesion 69 and the guide pin 50 . The threaded retrodrill guide pin 50 is inserted and engaged with the threads of the cannulated retrodrill cutter 10 by rotating and advancing the guide pin 50 in the direction of arrow F ( FIG. 4 ) with respect to the retrodrill cutter 10 . Optionally, placement of retrodrill cutter 10 employs a grasper or a similar device (not shown), for example.
[0029] Once engaged within the retrodrill cutter 10 , the cannulated retrodrill guide pin 50 is chucked into a rotary driver and retracted until the proximal face of retrodrill cutter 10 contacts the tibial plateau 63 and lesion 69 . At this point, a first reading of the markings 56 on the cannulated retrodrill guide pin 50 is recorded relative to anterior tibial skin surface 61 .
[0030] The cannulated retrodrill guide pin 50 is then rotated and retracted so that the proximal cutting face of retrodrill cutter 10 cuts through the surface of osteochondral lesion 69 and into the underlying bone, thereby forming a tibial recipient socket 100 as shown schematically in FIG. 7 , in which representations of the surgical apparatus having been omitted for clarity. A second reading of the markings 56 on the retrodrill guide pin 50 , recorded relative to the anterior tibial skin surface 61 , is used to gauge the depth D of the retrodrill cutter 10 into the tibia 66 . For example, once the first reading of the markings has been recorded, the surgeon could count about thirty markings 56 to the second reading, which would correspond to a depth D of about 5 to about 10 millimeters depending upon the mark spacing.
[0031] After drilling the retrodrill cutter 10 into the tibia 66 and completing the socket, the retrodrill guide pin remains in place, and is advanced to urge cutter 10 out of the socket. The retrodrill cutter 10 is disengaged from the retrodrill guide pin 50 by a reverse drilling motion, in the direction of arrow R of FIG. 6 . The retrodrill cutter 10 is disengaged from the end of stand 43 , by cutting the strand, for example. The end of strand 43 is secured to remain in place and available in the joint space by tying a knot, for example, to prevent the strand from being pulled back through cannulated body 53 .
[0032] Reference is now made to FIG. 8 , which shows the retrograde insertion of an osteochondral core or plug 46 into the recipient socket 100 of tibia 66 . The core 46 is developed, for example, as a cannulated plug formed of a translucent or transparent polymer material, and preferably made of bioabsorbable materials such as polyglycolic or polylactic acid polymers. Optionally, core 46 is an autograft or autogenous bone core, or an allograft core, harvested by known methods of the art and subsequently employed in the retrograde osteochondral repair method of the present invention. Alternatively, the core 46 is a synthetic implant plug formed from a synthetic hydrogel, preferably Salubria™, having various shapes, preferably a cylindrical shape with one end being curved to match a portion of an articular surface. Salubria™ is a hydrogel composition, which is similar to human tissue in its mechanical and physical properties, and is sold by Salumedica of Atlanta, Ga.
[0033] Strand 43 is inserted through an opening formed through core 46 , and is secured to the back end of the core by a ball or knot 44 ( FIG. 8 ). If desired, the knot 44 is countersunk into the core 46 for permanent suture fixation. Alternatively, strand 43 is attached to core 46 by insert molding or adhesive.
[0034] The suture strand or wire 43 extending from the core 46 is passed outside the tibia, preferably through the lumen of cannulated body 53 of guide pin 50 , the trocar 58 having been removed. Optionally, when using a non-cannulated guide pin, for example, strand 43 passes directly through the tunnel 67 . The free end of strand 43 is captured outside the body and retracted to draw the suture or wire 43 through the guide pin 50 . As the strand 43 is drawn, the core 46 is pulled into the joint space and pivoted into axial alignment with the tibial recipient socket 100 . Continued tension on strand 43 draws core 46 into the tibial socket 100 in a retrograde fashion. One skilled in the art will realize that the amount of force for advancing the core 46 into the tibial recipient site 100 is directly proportional to the diameter and length (L) of the core 46 , as well as the depth of the tibial socket 100 .
[0035] Once the core 46 is secured within the tibial socket 100 , the strand 43 exiting the lateral opening of the tibia can be secured with a button or a small diameter T-screw provided over or in the hole and substantially flush with the cortical bone. Alternatively, the strand 43 is removed, for example, by grasping the ball or knot 44 with a grasper or a similar device and drawing the strand out through the joint space. If complications occur, such as over-insertion of the core 46 , the cannulated retrodrill guide pin 50 is employed to push the core out of the tibial site for corrections.
[0036] Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. | Osteochondral sockets are formed using a retrograde drill assembly. The retrograde drill assembly includes a guide pin having a fluted tip and an externally threaded portion. A removable cutter head has internal threads that engage the threads of the guide pin. The guide pin is drilled through bone, exposing the external threads in a joint space requiring repair. The cutter is threaded onto the guide pin, and the assembly is retrograded with rotation to form a socket in the bone. The cutter is disengaged from the guide pin for disassembly and removal from the bone, making way for an implant to be installed in the pocket. The implant can be drawn into the socket using an attached strand threaded through the bone socket and out of the bone. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to the field of delivery devices and, more particularly, to a method of producing rapidly dissolving pharmaceutical tablets.
2. Description of the Related Art
Many people, particularly the young and the elderly, have difficulty swallowing orally administered medications. These difficulties may arise from an inability to chew and/or swallow pills and tablets. Tablets that disintegrate rapidly, and preferably without water, are therefore highly desirable.
To achieve rapid dissolution, tablets need to be sufficiently porous. However, the tablet must also maintain its integrity prior to administration. Therefore, a need exists for a rapidly disintegrating tablet having enhanced structural integrity.
U.S. Pat. No. 4,134,943 describes a process for developing a fast dissolving tablet that requires a solvent that is inert to all components of the tablet. After mixing of all the components in the solvent, the mixture is frozen and pressed into a tablet. The solvent is then evaporated to form the porous tablet. The process is complex and quite expensive.
Another freeze drying process for forming porous tablets is described in U.S. Pat. No. 4,371,516. A gelatin or other water-soluble binder along with the pharmaceutical and acceptable sugars are all dissolved and the mixture placed in a suitable mold. The mixture is frozen and the solvent removed under vacuum. The tablets are expensive to prepare and require special packaging due to their lack of strength.
U.S. Pat. No. 5,516,530 describes an even more complex system for forming porous tablets using lyophilization. U.S. Pat. No. 5,298,261 describes a freezing process followed by vacuum drying that makes for a less porous tablet than is seen in the prior lyophilization processes.
U.S. Pat. No. 3,885,026 describes the incorporation of a readily volatilizable solid excipient into a tablet, producing a porous yet strong shape after sublimation. Dissolving times are listed at 105 to 270 seconds, which is too long for the purposes to which the present invention is directed.
A further weakness in the prior art methodologies relates to the dissolution or suspension of all components in water. When excipients as well as the active ingredients are dissolved, this precludes the use of controlled release or coated active ingredients for taste masking. More particularly, during preparation of the aqueous suspension prior to freeze drying, the coated particles can release a sufficient amount of the active ingredients to render the final tablet, after drying, unpalatable. Accordingly, a need exists for a methodology in which all dry ingredients can be used, without the need for water, so as to maintain taste masking while yet creating the requisite tablet porosity for fast dissolution.
SUMMARY OF THE INVENTION
In view of the foregoing, one object of the present invention is to overcome the difficulties that some patients encounter with orally administered medications through the production of a tablet that dissolves quickly in the mouth, allowing for effortless swallowing without any need for drinking water.
Another object of the invention is to produce a fast-dissolving tablet by optimizing component particle size ranges to promote both optimum release and tablet strength.
A further object of the invention is to produce a tablet having sufficient strength by controlling the amount of excipient within specified ranges.
A still further object of the invention is a tablet that does not require suspension of all components in water during formation and therefore allows for effective taste masking of the active ingredient.
Yet a further object of the invention is a tableting process that is cost effective, requiring only commercially available raw materials and standard tablet dies and associated machinery.
In accordance with this and other objects, the present invention is directed to a method of producing a fast-dissolving pharmaceutical delivery device of moderate strength. The formulation employed in the method utilizes at least one carbohydrate, a strengthening polymer, a volatile pore-forming excipient, and a physiologically active ingredient. By controlling and optimizing the particle size distribution ranges of the components prior to tablet formulation, particularly of the pore forming excipient, a much faster releasing tablet is obtained.
These and other objects of the invention, as well as many of the intended advantages thereof, will become more readily apparent when reference is made to the following description taken in conjunction with the accompanying examples.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In describing a preferred embodiment of the invention, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
According to the present invention, the method of formulation utilizes one or more carbohydrates, a polymer for improving tablet strength, a volatile excipient such as ammonium bicarbonate, along with taste masking flavorings and a physiologically active ingredient. The carbohydrates may be one or more of the following examples: lactose, mannitol, sorbitol, fructose or other highly water-soluble sugar or sugar alcohol.
Particle sizes and the nature of the carbohydrate can affect both the strength and the taste of the final tablet. Lactose and sorbitol combinations are the most favorable for improving the rate of dissolution, with sorbitol concentration at approximately 10 to 35% of the pre-processed tablet mass and more specifically, 15 to 20%. Lactose concentration at 15 to 50% also proved effective, with the optimum being 30% to 40% of the pre-processed mass. Processing as defined herein is the removal by sublimation of the volatile tablet component.
Sorbitol is employed for its pleasing taste-modifying properties while the lactose is used for its superior dissolution property. Mannitol can be substituted for the lactose with only a slight decrease in disintegration time. Small amounts of maltodextrin improve the tablet strength but with the sacrifice of release time.
Sugar particle size is optimized to improve the strength and the dissolution times, with a particle size below 75 microns being desirable and, more specifically, 37 to 70 microns being optimal.
A volatile excipient such as ammonium carbonate or ammonium bicarbonate is known to create porosity in the tablet after it is heated under a vacuum for several hours. However, according to the present invention, the disintegration times of the final tablets are markedly reduced if finely ground ammonium carbonate is used. More particularly, the disintegration times as measured in a rotating basket submerged in water are greatly reduced when all of the particles of ammonium carbonate are below 70 microns in size, and preferably in the range of 37 to 70 microns. The use of even finer particles of carbonate produced only slight improvement in disintegration times.
Ammonium carbonate and ammonium bicarbonate may be used somewhat interchangeably in accordance with the present invention. Therefore, references herein to ammonium carbonate shall be understood to include the use of ammonium bicarbonate in place thereof, and vice versa. However, in practice it is noted that carbonate is preferred since water is not present during decomposition.
Controlling particle size in accordance with these ranges not only decreases the release time but increases the ultimate tablet strength. The tablet appearance is also considerably improved since there are no large pores evident on the tablet surface as occur with the use of larger particles of bicarbonate.
The smaller ammonium bicarbonate particles produce somewhat weaker tablets. Tablets made with ammonium bicarbonate sieved below 38 microns were approximately 40% weaker than those containing ammonium bicarbonate sieved below 100 microns (average size of about 60 microns). However, this reduction in strength was ameliorated, without greatly sacrificing the disintegration time, by employing ammonium bicarbonate sieved below 53 microns.
The amount of bicarbonate used in forming a tablet (pre-processed mass) also has a profound effect on disintegration, more so than its effect on tablet strength. For example, a half-inch diameter tablet with a pre-processed mass of 500 mg pressed at the same pressure showed a 40% slower release at 25% ammonium bicarbonate than a tablet containing 35% bicarbonate with the other ingredients in equal ratios. The difference in strength between the two tablets was minimal, with the 25% tablet being slightly stronger. Therefore, within a narrow range of concentration, the bicarbonate content can be increased to improve disintegration without unduly sacrificing tablet strength.
Small amounts of microcrystalline cellulose, starch, or maltodextrin can improve the strength of the tablets without significant increase in disintegration times. Particle size for these excipients was of less importance with regard to impact on the disintegration times. Approximately 2% to 8% of each of microcrystalline cellulose (for example, Avicell® of FMC) and starch (as Starch 1500, Colorcon, e.g.), more specifically 5% each, gave improved tablet strength. Small amounts of polyvinyl pyrolidone (ISP K-30), up to approximately 3%, gave improved strength without greatly affecting release times. The addition of mannitol also gave improved strength to the tablets without greatly sacrificing the dissolution behavior.
The following examples are given for the purpose of illustrating the present invention. The tablet dissolution performance was measured using a rotating basket procedure. Release times were measured by placing the tablet in a small wire basket placed on the end of a rod spinning at 100 rpm. This was placed in water and the dissolution time was noted when the tablet was completely disintegrated and there were no pieces retained by the basket screen.
EXAMPLE 1
Ammonium carbonate, microcrystalline cellulose, polyvinyl pyrolidone, mannitol and sorbitol were combined to form 400 mg of the mixture as follows:
Ingredients
Percentage to Total
Ammonium carbonate
35%
microcrystalline cellulose
10%
(Avicell ® 101, FMC)
polyvinyl pyrolidone
10%
(K-90, ISP)
mannitol (as received;
20%
Aldrich Chemical)
sorbitol (as received;
25%
Aldrich Chemical)
The mixture was placed in a 1 cm tablet die and approximately 3000 pounds of force was applied. The tablets were then heated at 60° C. in a vacuum oven for three hours.
When ball-milled ammonium carbonate was used, the resulting tablet disintegrated completely in 5 seconds.
When ammonium carbonate as received from the supplier was used, the resulting tablet disintegrated in approximately 7 seconds.
EXAMPLE 2
Ammonium carbonate, microcrystalline cellulose, polyvinyl pyrolidone, mannitol and sorbitol were combined to form 1 gm of the mixture as follows:
Ingredients
Percentage to Total
Ammonium carbonate
25%
(ground and sieved below 53 microns)
microcrystalline cellulose
10%
(Avicell ® 101)
polyvinyl pyrolidone
10%
(K-90, ISP)
mannitol (as received)
35%
sorbitol (as received)
20%
The mixture was pressed in a 21 mm (0.875 inch) tablet die and approximately 2000 pounds of force was applied. The tablets were then heated under vacuum at 60° C. for three hours.
The disintegration time for the average of three tablets was just over 3 seconds.
EXAMPLE 3
Ammonium carbonate, microcrystalline cellulose, lactose, sorbitol and starch were combined to form 800 mg of the mixture as follows:
Ingredients
Percentage to Total
Ammonium carbonate
15%
microcrystalline cellulose
5%
lactose
50%
sorbitol
25%
starch
5%
(Starch 1500, Colorcon)
The mixture was placed in a ⅝ inch tablet die and approximately 2000 pounds of force was applied. The tablets were then heated under vacuum at 60° C. for four hours.
When the ammonium carbonate used had been ground and sieved below 53 microns, the resulting tablets disintegrated in 30 seconds.
When the ammonium carbonate was used as received (without grinding), the resulting tablets disintegrated in 42 seconds.
EXAMPLE 4
Ammonium carbonate, microcrystalline cellulose, lactose, sorbitol and starch were combined to form 800 mg of the mixture as follows:
Ingredients
Percentage to Total
Ammonium carbonate
25%
(ground and sieved below 53 microns)
microcrystalline cellulose
5%
lactose
42%
sorbitol
23%
starch
5%
(Starch 1500, Colorcon)
The mixture was placed in a ⅝ inch tablet die and approximately 2000 pounds of force was applied. The tablets were then heated under vacuum at 60° C. for four hours.
The resulting tablets disintegrated in 13 seconds. This is faster than the tablets in example 3, in which only 15% carbonate was used, even when the ammonium carbonate had been ground and sieved below 53 microns.
EXAMPLE 5
Ammonium carbonate, microcrystalline cellulose, lactose, sorbitol and starch were combined to form 1 gm of the mixture as follows:
Ingredients
Percentage to Total
Ammonium carbonate
25%
(ground and sieved below 53 microns)
microcrystalline cellulose
5%
(Avicell ® 101, FMC)
lactose
40%
sorbitol
25%
starch (Starch 1500, Colorcon)
5%
The mixture was pressed in a ⅝ inch tablet die and compressed. One group of tablets from this mixture was pressed at 2000 psi and another group was pressed at 2500 psi. All of the tablets were then heated in a vacuum oven at 65° C. for four hours.
The tablets pressed at the lower pressure disintegrated in 13 seconds, while those pressed at the higher pressure disintegrated in 26 seconds.
EXAMPLE 6
Ammonium carbonate, microcrystalline cellulose, mannitol, sorbitol and starch were combined to form 800 mg of the mixture as follows:
Ingredients
Percentage to Total
Ammonium carbonate
25%
(ground and sieved below 53 microns)
microcrystalline cellulose
5%
(Avicell ® 101, FMC)
mannitol granules
40%
(SD200, Roquette America)
sorbitol
25%
starch (Starch 1500, Colorcon)
5%
A mixture of the mannitol, sorbitol, and starch was granulated in a small planetary drive mixer by the addition of atomized water on the mixture as it was mixing. After drying, the granules were mixed with the carbonate and microcrystalline cellulose, and 800 mg of the mixture was pressed in a ⅝ inch tablet die and compressed at 2000 psi. The tablets were then heated in a vacuum oven at 60° C. for four hours.
The disintegration time was approximately 10 seconds.
The foregoing descriptions and drawings should be considered as illustrative only of the principles of the invention. The invention may be configured in a variety of shapes and sizes and is not limited by the dimensions of the preferred embodiment. Numerous applications of the present invention will readily occur to those skilled in the art. Therefore, it is not desired to limit the invention to the specific examples disclosed or the exact construction and operation shown and described. Rather, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A method of producing a fast-dissolving pharmaceutical delivery device of moderate strength. The delivery device is a fully formed tablet composed of readily available sugars, strength polymers and a volatilizable excipient along with an active ingredient and optional flavorings. The tablet as made will disintegrate in an aqueous medium such as saliva in under 15 seconds, making mastication unnecessary or at least requiring only one or two bites on the tablet. Essential to the invention is the easily obtainable particle size ranges of the sugars and the volatilizable excipient which promotes optimum release and tablet strength. The invention also allows for effective taste masking of the active ingredient with standard particle coating techniques. | 8 |
This application is a division of U.S. patent application Ser. No. 104,789, filed Aug. 10, 1993, now U.S. Pat. No. 5,388,549.
FIELD OF THE INVENTION
This invention relates generally to milk sampling for diagnostic purposes, and more specifically to a method and apparatus for extracting a sample of milk to be tested from the milk line in a milking system, whilst substantially avoiding interruption of the routine milking procedure.
BACKGROUND OF THE INVENTION
Milking of an animal is effected by means of a claw having attached thereto cups which are connected to the animals teats. In the mechanised situation which exists in a milking installation, a milk line connects to the claw to receive the milk. In order to draw off the milk, a constant vacuum of about 0.5 Bar is applied to the milk line, switchable on and off by a valve. The vacuum is switched on prior to commencement of milking and connects the cups to the teats. After milking has been completed, the vacuum is switched off. A second vacuum system provides a pulsating vacuum to the outside of the liners, to stimulate milk flow and maintain blood circulation in the teats. It will be understood, therefore, that in the environment of a milking installation, there are generally available two sources of vacuum namely a constant or steady vacuum and a pulsating vacuum.
THE INVENTION
According to one aspect of the present invention, there is provided a method of extracting a sample of milk from a milk line to which a vacuum is applied, for extracting milk from an animal, according to which a portion of the milk is a milk/air mixture flowing in the milk line is diverted through a by-pass, in which is provided an extraction means operable by at least one of a fixed vacuum and a pulsating vacuum for separating from the milk flowing in the by-pass a sample thereof and delivering it to a testing device.
The said extraction means may also serve to control activation of the testing device for the purpose of testing the extracted milk sample.
Initiation of an operating cycle to the sample extracting means may be effected manually.
Preferably, in an upstream part of the sample extracting means, the milk flowing in the by-pass is raised to a pressure slightly above atmosphere pressure. This is desirable in order to cause the sample of milk to be delivered to the testing device, notwithstanding the vacuum which is appplied to said by-pass to cause milk to be drawn through the milk line when said means is not delivering a sample.
Preferably, the operating cycle of the sample extracting means is timed, and milk is delivered to the testing device only for a portion of said operating cycle. Thus, according to another aspect of the invention, there is provided a method of extracting a sample of milk from a milk line to which a vaccuum is applied for extracting milk from an animal, according to which a portion of the milk flowing in the milk line is diverted through a by-pass, in which is provided an extraction means operable by at least one of a fixed vacuum and a pulsating vacuum for separating a sample from the milk flowing in the by-pass and delivering the sample to a testing device, the extraction means being operable over an operating cycle which is timed. When the sample extracting means also controls activation of the testing device, the latter may be activated for a subsequent portion of the operating cycle.
Preferably, at the junction where the by-pass connects to the milk line, the line is so formed as to produce a reservoir of milk. In this way a constant flow of milk is generated through the by-pass.
In a preferred method, at a delivery device from which milk is delivered to the testing device, when the delivery device is restored to open the by-pass to a through flow of milk, a temporary inflow of air through the delivery device caused by the vacuum applied in the by-pass, cleans the delivery device of residual milk.
Preferably, when the milk line is cleaned by flushing with cleaning fluid following the completion of a milking operation, the cleaning fluid also passes through the by-pass to clean the sample extracting means and delivery device.
The invention also relates to sample extracting apparatus for carrying out the above described method.
According to another aspect of the invention there is provided apparatus for extracting a sample of milk from a milk line to which a vacuum is connectable, the milk line in use being connected to an animal being milked, comprising a sample extracting means for passing a flow of milk received from the milk line, said means comprising a pump for pressurizing milk and for operating a timer, and a sampling valve receiving the pressurized milk and for delivering a sample of milk to a diagnostic testing device, said sampling valve being operable under control of the timer.
Preferably the milk pump and the sample valve are vacuum operated.
Where a pulsating vacuum is available, the milk pump may to advantage be operated by the pulsating vacuum, whilst the sampling valve is preferably operated from a source of steady vacuum.
The testing device may also be an actuable device for carrying out the diagnostic test, and this device also may be operable by a steady vacuum under control of the timer.
If desired a plurality of testing devices for carrying out different diagnostic tests may be similarly operated and controlled.
One such diagnostic test may be a test for progesterone content of the milk.
A preferred pump is single acting reciprocating pump. The linear stroke of the pump piston is preferably converted to a rotary movement by a suitable transmission device, for example a double-ratchet mechanism which indexes a gear wheel on both the forward and reverse strokes of the pump.
In a preferred embodiment, the timer is driven by the transmission device through reduction gearing. In the timer, one or more timing cams are driven through a clutch, such as a wrap spring clutch, which includes a manually operable release, eg. a pawl. When the pawl is released, as by a push-button, an operating cycle is initiated during which the timing cam or cams are permitted to perform one complete revolution. A camming surface on one of the timing cams mechanically controls a valve which opens a steady vacuum to the sampling valve for a portion of the operating cycle, thereby diverting the pressurized flow of milk through the sampling device to the testing device. During a later portion of the operating cycle, a camming surface on another timing cam may in similar manner cause activation of the testing device. Except when the sampling valve is operated, milk flows through the pump and the sampling valve. Thus, when the milk line is flushed following a milking operation, cleaning fluid also flows through the sampling means.
In a preferred sampling system, the sampling means is connected as a by-pass to a primary milk line. Preferably, at the junction where the by-pass joins such milk line, a collector is provided in the milk line to collect and retain a reservoir of the flowing milk. In this way, milk flows continously through the by-pass, even though the primary milk line is erratically passing a flow of milk, froth and air.
DESCRIPTION OF EMBODIMENTS
The method and apparatus in accordance with the invention are exemplified in the following description, making reference to the accompanying drawings, in which:
FIG. 1 is a block diagram of a sampling system;
FIGS. 2 and 3 show a sampling pump and timer unit respectively in two side views;
FIG. 4 shows a detail of the pump and timer unit;
FIGS. 5 and 6 show a sampler valve, respectively in non-operated and operated conditions; and
FIGS. 7 and 8 show an actuable testing device, respectively in elevated and plan views.
FIG. 9 illustrates the milk collector of FIG. 1.
Referring to FIG. 1, the sampling system is connected to a milk line 10 to which a vacuum is applied during milking and through which, in use, is flowing milk being collected from an animal being milked. In fact, in use the line 10 is passing a mixture of milk, froth and air.
The sampling system is in the form of a by-pass connecting to the milk line at a collector 12, which is simply a portion fitted into the milk line having a depressed base, so as to form a reservoir for milk. By virtue of the collector 12, milk flows through the sampling system in the form of a continous stream.
In addition to the collector 12, the sampling system includes a pump and timer unit 14 and a sampling valve 16. An actuable testing device 18 may also be regarded a part of the system. In FIG. 1, the solid black line indicates milk flow, the dotted line indicates an applied fixed vacuum, and the dash-dotted line indicates an applied pulsating vacuum.
A pulsating vacuum is applied to operate the pump and timer unit. The timer controls the application of a steady vacuum for operating the sampling valve and the testing device.
The pump and timer unit 14 as depicted in FIG. 3 comprises a pump on the left-hand side and a timer on the right-hand side. The pump comprises an upper chamber 20 in the upper part of which reciprocates a diaphragm-supported piston 22 under the action of a pulsating vacuum applied at the inlet port 2 4 and of a return spring 26.
The pump also has a lower chamber 28 in which reciprocates a diaphragm-supported secondary piston 30. The lower chamber has a milk inlet 32 and a milk outlet 34, each associated with a one-way valve 36, whereby milk entering the pump, under the influence of the vacuum applied to the milk line, is raised in pressure to slightly above atmospheric pressure. The pressurized milk then passes to the sampling valve 16.
As shown in FIG. 4, the piston 22 in the upper chamber 20 drives a double ratchet mechanism in the form of gear wheel 38 and oppositely acting pawls 40, whereby the linear motion of the piston is converted into a stepped rotary movement of the gear wheel. The gear wheel 38 drives the timer. Thus, reverting to FIGS. 2 and 3, the gear wheel 38 couples, through reduction gearing 42, 44 with a disc 46 forming part of a wrap spring clutch 48 carried by a shaft on which are also mounted two timing cams 50, 52. The camming surface 54 on one of these cams is visible in FIG. 2.
The wrap spring clutch also includes a pawl 56 normally engaging with a step in the periphery of the disc 46, therby to prevent rotation of said disc, whereby the timing cams are also held against rotation. However, the pawl 56 can be lifted by, for example, a manually depressed push-button 58, thereby causing the clutch spring to tighten and, start an operating cycle of the timer in which one complete revolution of the shaft carrying the disc and the timing cams takes place. In practice, such an operating cycle occupies about 300 strokes of the pump, taking about 5 minutes.
The timing cams mechanically control two valves, one of which is shown in FIG. 2, one controlling application of the steady vacuum to the sampling valve 16 and one controlling application of the steady vacuum to the testing device 18.
The sampling valve is shown in FIGS. 5 and 6, and comprises a valve member 60 having a head 62 in a milk chamber 61 which passes milk received from the pump, the milk entering at port 65 and leaving at port 67. The valve member 60 is operable by movement of a diaphragm acting thereon via member 63. Thus, when the timing cam 50 causes the steady vacuum to be applied at the inlet port 64, the valve member 60 is lifted for a short period during which a sample of milk is delivered from outlet 66, from the milk chamber, to the testing device. When the steady vacuum is withdrawn from the inlet port 64, spring 68 returns the valve member to the closed position.
It is to be noted that, except when the valve member is operated, there is a through-flow of milk through the milk chamber back to the milk line so that the milk delivered to the testing device is representative of the milk flowing through the milk line at that instant. It also follows that, when the system is flushed with cleaning fluid after completion of a milking Operation, the sample valve is also washed clean. Moreover, when the valve member is restricted to close the milk sample outlet, a momentary back surge of air occurs through said outlet, due to the applied vacuum in the milk line, which sucks any milk clinging to the mating surfaces of the valve member and valve seat back into the milk chamber.
The diagnostic testing device per se forms no part of the present invention. As illustrated in FIGS. 7 and 8, however, it comprises upper and lower relatively rotatable cups, respectively 70 and 72, with openings in the base of the upper cup which can be aligned with or closed off from reagent chambers in the lower cup. The milk sample is retained in the upper cup until the cups are relatively rotated to release some of the milk sample into the reagent chambers.
Relevant to the present invention is the actuator means for effecting the necessary relative rotation of the cups. This occurs after the milk sample has been delivered to the upper cup from the sampling valve, which is ensured by appropriate positioning of the camming surface on the timing cam 52 relative to that of the camming surface in the timing cam 50 which controls the sampler valve.
As shown in FIG. 8, in particular, the actuator means comprises a ratchet 74 on a cylindrical member 76 which is sealingly slideable relative to a fixed cylindrical member 78 under the influence of the steady vacuum, when applied at inlet port 80. Ratchet 74 drives a gear 82 carried by the rotatable cup. Restoration of the member 76 is by means of an internal spring 84.
It will be appreciated that, by providing more timing cams on the timer of FIGS. 2 and 3, it is possible to actuate more than one actuable testing device, for carrying out different diagnostic tests, or to actuate a testing device requiring more than one actuation.
Various modification of the above-described and illustrated arrangement are possible within the scope of the invention hereinbefore defined. In particular, for carrying out the method generally illustrated in FIG. 1, various other constructions of pump, timer and sampling valve, operable by steady and/or pulsating vacuum, may be employed.
FIG. 9 illustrates the milk collector 12 of FIG. 1. Milk 13 collects in the depression 15 and is drawn off along tube 17 to the pump and timer unit 14. | Methods and apparatus enabling a diagnostic test to be carried out on milk flowing in a milk line from an animal being milked, without interrupting the milking process, in which a portion of the milk is diverted through a by-pass in which an extracting means (14) in the form of a vacuum-operable pump and timer acts to separate from the milk flowing in the by-pass a milk sample and to deliver said sample through an associated sampling valve (16) to a testing device (18). | 0 |
This is a divisional of co-pending application Ser. No. 06/917,640 filed on Oct. 8, 1986, now U.S. Pat. No. 4,684,439.
BACKGROUND OF THE INVENTION
In the manufacture of tissue products such as facial tissue, bath tissue, and paper toweling, softness is imparted to the product by adhering the web to a rotating creping cylinder and thereafter dislodging it from the creping cylinder with a doctor blade. In order for the creping process to be effective, it is necessary to obtain proper adhesion between the web and the creping cylinder, which is generally achieved by the addition of a creping adhesive. Very small amounts of adhesive are applied per revolution of the creping cylinder. For good creping, an adhesive coating must build up on the surface of the dryer and is continuously renewed during each revolution of the dryer as a small amount is removed by the doctor blade and replaced by freshly applied adhesive. The newly applied adhesive is incorporated into the existing coating, which is reactivated by taking on moisture from the fresh application. Therefore, rewettability is an important property of a good creping adhesive.
In an effort to seek new and improved creping adhesives, a water-soluble, thermosetting, cationic polyamide resin creping adhesive was developed as described in U.S. Pat. No. 4,501,640 to Soerens. However, although such a creping adhesive exhibits good adhesion, the thermosetting nature of such adhesives works against rewettability because after cross-linking (curing) the addition of moisture is no longer able to soften and conform the coating sufficiently to optimally bond with the tissue web at the pressure roll nip.
Therefore there is a need for an improved method of creping cellulosic webs which uses a creping adhesive exhibiting improved wettability.
SUMMARY OF THE INVENTION
It has now been discovered that a creping adhesive comprising an aqueous admixture of polyvinyl alcohol and a water-soluble, thermoplastic polyamide resin derived from poly(oxyethylene) diamine exhibits improved wettability and therefore improved performance in the creping process.
In one aspect, the invention resides in a creping adhesive comprising an aqueous admixture of polyvinyl alcohol and a water-soluble thermoplastic polyamide which is the reaction product of a polyalkylene polyamine, a saturated aliphatic dibasic carboxylic acid, and a poly(oxyethylene) diamine.
The polyvinyl alcohol component can be of any water-soluble molecular weight sufficient to form an adhesive film. Generally, a weight average molecular weight of from about 90,000 to about 140,000 is preferred. Polyvinyl alcohol in solid form is commercially available under several trademarks such as GELVATOL® (Monsanto), VINOL® (Air Products), ELVANOL® (DuPont) and POVAL® (Kuraray). Suitable commercially available grades have a viscosity of from about 13 to about 50 centipoise for a 4% aqueous solution at 20° C. These grades have a degree of hydrolysis of from about 80 to about 99.9 percent. Those skilled in the art will appreciate that lowering the degree of hydrolysis and the molecular weight will improve water solubility but will reduce adhesion. Therefore the properties of the polyvinyl alcohol will have to be optimized for the specific application.
The water-soluble thermoplastic polyamide resin component of the creping adhesive comprises a reaction product of a polyalkylene polyamine, a saturated aliphatic dibasic carboxylic acid, and a poly(oxyethylene) diamine. The polyalkylene polyamine component has the formula
NH.sub.2 (C.sub.n H.sub.2n HN).sub.x H
wherein n and x are each integers of 2 or more. The aliphatic dibasic carboxylic acid component has the formula
HOOC--R--COOH
wherein "R" is a divalent aliphatic radical having from 1 to 8 carbon atoms. The poly(oxyethylene) diamine component has the formula ##STR1## wherein "a" is 1 or 2, "b" is from 5 to 50, and "c" is 1 or 2. Preferably, "a+c" averages about 2.5 and "b" averages about 8.5.
An essential characteristic of the resins of this invention is that they are phase-compatible with the polyvinyl alcohol, i.e., they do not phase-separate in the presence of aqueous polyvinyl alcohol.
In another aspect, the invention resides in a method for creping cellulosic webs comprising (a) applying to a rotating creping cylinder an aqueous admixture containing from about 90 to about 99.95 weight percent water and from about 0.05 to about 10 weight percent solids, wherein from about 20 to about 90 weight percent of said solids is water-soluble polyvinyl alcohol and wherein from about 10 to about 80 weight percent of said solids is a water-soluble, thermoplastic polyamide resin which is phase-compatible with the polyvinyl alcohol, said polyamide resin comprising the water-soluble thermoplastic reaction product of a polyalkylene polyamine, a saturated aliphatic dibasic carboxylic acid, and a poly(oxyethylene) diamine; (b) pressing a cellulosic web against the creping cylinder to effect adhesion of the web to the surface of the cylinder; and (c) dislodging the web from the creping cylinder by contact with a doctor blade. Preferably, the aqueous admixture contains from about 0.1 to about 1.0 weight percent solids.
The invention will be described in greater detail with respect to the specific examples set forth below.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Example 1: Preparation of Polyamide Resin
83 grams (0.8 mole) of diethylene triamine, 146 grams (1.0 mole) of adipic acid, and 180 grams (0.3 mole) of a poly(oxyethylene) diamine (Jeffamine ED 600 manufactured by Texaco Chemical Co. and having the formula described above with "a+c" averaging 2.5 and "b" averaging 8.5) were added to a three-neck resin flask equipped with a mechanical stirrer, thermometer, and a water trap. The solution was heated to 160° C. and water collected over 105 minutes as the temperature rose to 195° C. The total amount of water collected was 30 ml (83.4% of theoretical). The contents of the flask were poured into a pan and cooled, solidifying into a yellow mass having a waxy feel. On standing the solid appeared to absorb water from the air to give a very tacky surface feel. A 2% solution of the product in distilled water at 20° C. had a specific viscosity of 0.19.
Example 2: Preparation of Creping Adhesive
A 5 weight percent aqueous solution of the polyamide prepared in Example 1 was combined with a 5 weight percent aqueous solution of a polyvinyl alcohol (PVA) having a weight average molecular weight of about 120,000 and a degree of hydrolysis of about 86%. The polyamide solution and the PVA solution were combined in various solids weight ratios of PVA/polyamide of from 90/10 to 30/70, respectively. No phase separation was observed in these blends.
Example 3: Water Uptake (Wettability)
Thin films of a 74/26 PVA/polyamide resin blend made as described above (this invention), and a thermosetting polyamide resin (control) were prepared by casting 5 weight percent solution into a silicone rubber mold at room temperature and allowing the water to evaporate. The resultant films, which were about 8 mils in thickness, were cut into strips of about 1×5 inches and "cured" in an oven at 200° F. for 15 minutes. After cooling to room temperature, the film strip was weighed to determine its dry weight. The film sample was then immersed in water at 72° F. for a time of 10, 30, 50, or 90 seconds. The sample was removed from the water on a wire mesh, shaken to remove surface drops of water, and weighed to determine the wet weight. The results are set forth in TABLE I.
TABLE I______________________________________Water Uptake Rates Wet Weight/Dry Weight RatioTime (Seconds) Control This Invention______________________________________0 1.0 1.010 1.47 1.8030 1.68 1.9450 1.72 2.4090 2.01 2.68______________________________________
As the results illustrate, the thermoplastic films of this invention take up water to a greater extent and at a greater rate than the thermosetting polyamide resin (control).
Example 3: Production of Facial Tissue
Facial tissue was made under controlled laboratory conditions using two different creping adhesives: a 0.1 weight percent solids solution of a blend of PVA and the thermoplastic polyamide of Example 1 in a 74/26 ratio of PVA to polyamide (this invention); and a 0.1 weight percent solids solution of a blend of PVA and a thermosetting polyamide resin in the same ratio (control).
The resulting tissues were tested for softness by a trained sensory panel which, on a 1 to 10 scale, rated the softness of the tissues made in accordance with the method of this invention at 7.2 compared to 6.8 for the control, illustrating improved creping performance.
The same tissue samples were also evaluated for stiffness using a mechanical device which measures the force required to crush a sample to a fixed degree. Measured crush loads were 53.9 grams for the samples made in accordance with this invention versus 64.7 grams for the control, illustrating that the tissues made in accordance with this invention were less stiff.
The foregoing examples illustrate the improved wettability of the thermoplastic polyamide creping adhesives of this invention and the utility of the method of this invention for making creped tissue products. | An improved wettable creping adhesive comprises an aqueous admixture of polyvinyl alcohol and a water-soluble thermoplastic polyamide resin comprising the reaction product of a polyalkylene polyamine, a saturated aliphatic dibasic carboxylic acid, and a poly(oxyethylene) diamine. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/302,747, filed on Nov. 22, 2002, the specification of which is incorporated herein by reference
FIELD OF THE INVENTION
[0002] This invention pertains to cardiac rhythm management devices and methods for operating such devices.
BACKGROUND
[0003] Tachyarrhythmias are abnormal heart rhythms characterized by a rapid heart rate, typically expressed in units of beats per minute (bpm). They can occur in either chamber of the heart (i.e., ventricles or atria) or both. Examples of tachyarrhythmias include ventricular tachycardia, ventricular fibrillation, atrial tachycardia, atrial flutter, and atrial fibrillation. Tachycardia is characterized by a rapid rate, either due to an ectopic excitatory focus or abnormal excitation by normal pacemaker tissue. Fibrillation occurs when the chamber depolarizes in a chaotic fashion with abnormal depolarization waveforms as reflected by an EKG.
[0004] An electrical shock applied to a heart chamber can be used to terminate most tachyarrhythmias. The electric shock terminates the tachyarrhythmia by depolarizing all of the myocardium simultaneously and rendering it refractory. A class of cardiac rhythm management devices known as an implantable cardioverter/defibrillator (ICD) provides this kind of therapy by delivering a shock pulse to the heart when the device detects fibrillation. ICDs can be designed to treat either atrial or ventricular tachyarrhythmias, or both, and may also incorporate cardiac pacing functionality for delivering either bradycardia pacing or anti-tachycardia pacing (ATP). In ATP, the heart is competitively paced with one or more pacing pulses in an effort to interrupt the reentrant circuit causing the tachycardia.
[0005] The most dangerous tachyarrhythmias are ventricular tachycardia and ventricular fibrillation, and ICDs have most commonly been applied in the treatment of those conditions. ICDs are also capable, however, of detecting atrial fibrillation and delivering a shock pulse to the atria in order to terminate the arrhythmia. Although not immediately life-threatening, it is important to treat atrial fibrillation for several reasons. First, atrial fibrillation is associated with a loss of atrio-ventricular synchrony which can be hemodynamically compromising and cause such symptoms as dyspnea, fatigue, vertigo, and angina. Atrial fibrillation can also predispose to strokes resulting from emboli forming in the left atrium. Although drug therapy and/or in-hospital cardioversion are acceptable treatment modalities for atrial fibrillation, ICDs configured to treat atrial fibrillation offer a number of advantages to certain patients, including convenience and greater efficacy. (As the term is used herein, atrial fibrillation should also be taken to include atrial flutter, which although clinically distinct, has similar consequences and may be treated similarly.)
[0006] Although atrial fibrillation can be successfully treated with electrical therapy from an implantable cardiac rhythm management device, it would be preferable to prevent an episode of atrial fibrillation from occurring. Another problem associated with defibrillation shock therapy is early recurrence of atrial fibrillation or ERAF. ERAF is defined as the recurrence of atrial fibrillation within a few minutes after successful cardioversion with atrial shock therapy. Certain patients are more prone than others to experience ERAF, and these patients may experience difficulty with repeated atrial defibrillation therapy. Reducing the incidence of ERAF would improve the efficacy of atrial defibrillation by electrical therapy and expand the population of patients for whom it is an acceptable therapy option.
SUMMARY
[0007] The length of the atrial effective refractory period (AERP) is one factor that determines the susceptibility of the atria to the onset of atrial fibrillation. By pacing the atria and delivering one or more non-excitatory stimulation pulses during the refractory period following each pace, the atrial effective refractory period can be extended. An implantable cardiac rhythm management device can be configured and programmed to deliver such AERP-extension pacing for a specified period of time automatically in response to a detected condition or in response to a command delivered by an external programmer. The non-excitatory stimulation pulses may be delivered in conjunction with any bradycardia atrial pacing mode. The bradycardia pacing mode may also employ overdrive pacing of the atria to increase the frequency of pacing and of non-excitatory stimulation for lengthening the AERP. The atrial sites where the pacing pulses and non-excitatory stimuli are delivered may the same or different. One particularly useful application of AERP-extension pacing is to lessen the occurrence of early recurrence of atrial fibrillation following delivery of electrical stimulation therapy to the atria in the form of either an atrial defibrillation shock or atrial anti-tachycardia pacing. AERP-extension pacing may also be delivered periodically during normal pacing as a preventative measure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an atrial action potential waveform.
[0009] FIG. 2 is a block diagram of an exemplary cardiac rhythm management device.
[0010] FIG. 3 shows the pacing events during AERP-extension pacing in relation to an ECG.
[0011] FIGS. 4A and 4B illustrate an exemplary system for overdrive pacing of the atria.
DETAILED DESCRIPTION
[0012] Atrial fibrillation is a condition in which the electrical activity of the atrium becomes very rapid and disorganized. Instead of the sinus node providing the normal excitation to the atrium, rapid circulating waves of abnormal waves of depolarization continuously stimulate the atrium, resulting in a rapid atrial rate that can exceed 400 beats per minute. Research has shown that a combination of slow intra-atrial conduction and a short atrial refractory period in the atrial myocardial substrate contribute to conditions necessary to sustain the multiple re-entrant waves of depolarization responsible for atrial fibrillation.
[0013] Like all excitable tissue, cardiac muscle cells are capable of generating a rapid change in transmembrane electrical potential, called an action potential, when the resting potential of the cell is depolarized to a threshold potential. The resulting depolarization then initiates the intracellular reactions responsible for mechanical contraction and propagates to adjacent cells as a wave of excitation that spreads throughout the myocardium. FIG. 1 illustrates an action potential AP of an atrial muscle cell as might be recorded from an intracellular electrode when the cell is excited due to either conduction of excitation from adjacent tissue or application of a pacing pulse. The action potential may be divided into an excitation phase 1 where the cell rapidly depolarizes, a plateau phase 2 where the depolarized state is maintained, and a repolarization phase 3 where the cell returns to its resting membrane potential. Myocardial cells are refractory to excitation for a period of time after being depolarized when no further action potentials can be generated. The refractory period can be subdivided into an absolute refractory period during which no stimulus is capable of exciting the cells and causing an action potential, and a relative refractory period during which a larger than normal stimulus is required to generate an action potential. The combination of the absolute and relative refractory periods in an atrial muscle cell is referred to as the atrial effective refractory period (AERP). As shown in FIG. 1 , the duration of the AERP corresponds roughly to the duration of the action potential.
[0014] The refractoriness of myocardial cells can be prolonged if the cells are stimulated during the refractory period with non-excitatory electrical pulses which can be either below or above the normal threshold potential for initiating an action potential. FIG. 1 shows an atrial pacing pulse A-pace that causes the action potential AP and which is then followed by a number n of non-excitatory stimulus pulses NES delivered during the plateau phase when the atrial cell is absolutely refractory. Since the cell is absolutely refractory, the non-excitatory stimulus pulses can be either subthreshold or suprathreshold. As shown in the figure, the application of the non-excitatory stimulus pulses causes extension of the AERP, effectively changing the atrial substrate and thus reducing the susceptibility of the tissue to fibrillation.
[0015] As described below, a cardiac rhythm management device can be configured to deliver atrial pacing together with non-excitatory stimuli during the refractory period after a pace to thereby extend the AERP. Such AERP-extension pacing may be employed to lessen the probability that atrial fibrillation will occur whenever conditions warrant, such as during the period following the application of an atrial defibrillation shock or atrial ATP therapy.
[0000] 1. Hardware Platform
[0016] Cardiac rhythm management devices are implantable devices that provide electrical stimulation to selected chambers of the heart in order to treat disorders of cardiac rhythm and include pacemakers and implantable cardioverter/defibrillators. Such devices are usually implanted subcutaneously on the patient's chest, and are connected to an electrode for each stimulated or sensed heart chamber by leads threaded through the vessels of the upper venous system into the heart. A pacemaker is a cardiac rhythm management device that paces the heart with timed pacing pulses. The term “pacemaker” as used herein should be taken to mean any device with a pacing functionality, such as an implantable cardioverter/defibrillator with a pacemaker incorporated therein.
[0017] In the description that follows, a microprocessor-based cardiac rhythm management device will be referred to as incorporating the system and method that is the present invention. In the embodiment to be described, the invention is implemented with a controller made up of a microprocessor executing programmed instructions in memory. It should be appreciated, however, that certain functions of a cardiac rhythm management device could be controlled by custom logic circuitry either in addition to or instead of a programmed microprocessor. As used herein, the terms “circuitry” or “programmed controller” should be taken to encompass either custom circuitry (i.e., dedicated hardware) or processor-executable instructions contained in a memory along with associated circuit elements.
[0018] FIG. 2 shows a system diagram of a microprocessor-based cardiac rhythm management device with pacing functionality that is suitable for delivering therapy to treat AF and to extend the atrial effective refractory period. The controller 10 of the device is a microprocessor that communicates with a memory 12 via a bidirectional data bus. The memory 12 may comprise, for example, a ROM (read-only memory) for program storage and a RAM (random-access memory) for data storage. The device has atrial sensing and pacing channels comprising electrodes 34 a - b , leads 33 a - b , sensing amplifiers 31 a - b , pulse generators 32 a - b , and atrial channel interfaces 30 a - b which communicate bidirectionally with microprocessor 10 . A ventricular sensing/pacing channel comprising electrode 24 , lead 23 , sensing amplifier 21 , pulse generator 22 , and ventricular channel interface 20 is also provided. The device may also have additional channels for sensing and/or pacing additional atrial sites or the ventricles. In the illustrated device, a single electrode is used for sensing and pacing in each channel, known as a unipolar lead. Other embodiments may employ bipolar leads that include two electrodes for outputting a pacing pulse and/or sensing intrinsic activity. The channel interfaces 30 a - b include analog-to-digital converters for digitizing sensing signal inputs from the sensing amplifiers and registers which can be written to by the microprocessor in order to output pacing pulses, change the pacing pulse amplitude, and adjust the gain and threshold values for the sensing amplifiers. A shock pulse generator 50 is interfaced to the controller for delivering atrial defibrillation shock pulses via a pair of shock electrodes 51 a and 51 b placed in proximity to an atrial region. A telemetry interface 40 allows for communicating with an external programmer.
[0019] The controller 10 controls the overall operation of the device in accordance with programmed instructions stored in memory, including controlling the delivery of paces via the pacing channels, interpreting sense signals received from the sensing channels, and implementing timers for defining escape intervals and sensory refractory periods. The sensing circuitry of the pacemaker detects a chamber sense when an electrogram signal (i.e., a voltage sensed by an electrode representing cardiac electrical activity) generated by a particular channel exceeds a specified detection threshold. A chamber sense may be either an atrial sense or a ventricular sense depending on whether it occurs in the atrial or ventricular sensing channel. Pacing algorithms used in particular pacing modes employ such senses to trigger or inhibit pacing.
[0020] The controller may also determine the intrinsic rate of the atria and/or ventricles by measuring the interval between successive senses. Atrial arrhythmias such as fibrillation can be detected in this manner using a rate-based criterion. The device may be configured to deliver electrical stimulation therapy to the atria when an atrial tachyarrhythmia is detected such as a defibrillation shock or atrial anti-tachycardia pacing. Upon such detection of atrial fibrillation, for example, the controller may be programmed to cause the delivery of a defibrillation shock to the atria. If subsequent sensing determines that the atrial fibrillation persists, the device may repeat the shock a specified number of times successful termination of the fibrillation is achieved. The device terminates atrial fibrillation by delivering a shock pulse to the atria, but the resulting depolarization also spreads to the ventricles. There is thus a risk that such an atrial shock pulse can actually induce ventricular fibrillation, a condition much worse than atrial fibrillation. The ventricles are especially vulnerable to induction of fibrillation by a depolarizing shock delivered at a time too near the end of the preceding ventricular contraction (i.e., close to the T wave on an EKG). The risk of inducing ventricular fibrillation can be reduced by delaying the delivery of an atrial shock pulse until the intrinsic ventricular rhythm is below a specified maximum rate and then delivering the shock synchronously with a sensed ventricular depolarization or R wave. The device may also have a shock pulse generator and shock electrode pair for delivering defibrillation shocks to the ventricles.
[0000] 2. Pacing Modes
[0021] Bradycardia pacing modes refer to pacing algorithms used to pace the atria and/or ventricles in a manner that enforces a certain minimum heart rate. Such modes are generally designated by a letter code of three positions where each letter in the code refers to a specific function of the pacemaker. Pacemakers can enforce a minimum heart rate either asynchronously or synchronously. In asynchronous pacing, the heart is paced at a fixed rate irrespective of intrinsic cardiac activity. Because of the risk of inducing an arrhythmia with asynchronous pacing, most pacemakers for treating bradycardia are programmed to operate synchronously in a so-called demand mode where sensed cardiac events occurring within a defined interval either trigger or inhibit a pacing pulse. inhibited demand pacing modes utilize escape intervals to control pacing in accordance with sensed intrinsic activity. In an inhibited demand mode, a pacing pulse is delivered to a heart chamber during a cardiac cycle only after expiration of a defined escape interval during which no intrinsic beat by the chamber is detected. For example, a ventricular escape interval can be defined between ventricular events so as to be restarted with each ventricular sense or pace. A pacemaker can also be configured to pace the atria on an inhibited demand basis. An atrial escape interval is then defined as the maximum time interval in which an atrial sense must be detected after a ventricular sense or pace before an atrial pace will be delivered.
[0022] Pacing protocols for ATP therapy can generally be divided into two classes: those that deliver one or more pulses in timed relation to detected depolarizations and those that deliver a continuous pulse train for a specified time beginning after a detected depolarization. Both types of ATP protocols attempt to block the reentrant depolarization wavefront causing the tachycardia with a second depolarizing wavefront produced by a pacing pulse. Protocols of the first group may vary according to parameters that define the number of pulses delivered and the particular timing employed. Protocols of the second group include so-called burst pacing in which a short train of pulses is delivered for a specified time and may vary according to parameters that define the duration, frequency, and timing of the pulses.
[0000] 3. Device Configuration
[0023] A device such as illustrated in FIG. 2 may be configured to deliver atrial pacing with atrial effective refractory period extension in a number of ways. In an exemplary dual-site configuration, the electrode of a first pacing channel is disposed in the right atrium for pacing that atrium, and the electrode of a second pacing channel is placed near the left atrium via the coronary sinus for delivery of the non-excitatory stimuli. Other configurations may use an atrial pacing channel and one or more dedicated stimulation channels where the pacing and one or more non-excitatory stimulus electrodes are placed at multiple atrial sites. Other devices may use the same pacing channel and electrode for delivering both pacing and non-excitatory pulses in a single-site configuration. With either a single-site or multiple-site configuration, the controller of the device is programmed with an AERP-extension mode that paces an atrium via the pacing channel using a bradycardia pacing mode and delivers one or more non-excitatory stimuli after a pacing pulse as described above. FIG. 3 shows an example of events in the pacing channel or channels PC in relation to an ECG. An atrial pacing pulse AP is followed by n non-excitatory stimulation pulses NSP, where the pulses NSP are delivered during the atrial refractory period and hence their amplitudes may be either above or below the threshold voltage needed to excite the atrial tissue. The atrial refractory period is defined in the programming of the device as a specified time period following the atrial pace. The atrial refractory period may be individually defined for a particular patient or selected as a nominal value representing the refractory period of a typical atrial fiber (e.g., 150 ms).
[0000] 4. Overdrive Pacing
[0024] The bradycardia pacing mode employed with the AERP-extension mode is preferably an inhibited demand mode where atrial senses inhibit atrial paces. Since the non-excitatory stimuli that extend the refractory period are only output during paced beats, it may be desirable to increase the frequency of atrial pacing by decreasing the atrial escape interval so that the pacing rate is greater than the intrinsic heart rate, termed overdrive pacing. Such an overdrive atrial pacing mode may be implemented by dynamic adjusting the atrial escape interval so that the interval is decreased when an atrial sense is detected and slowly increased after each paced beat.
[0025] In one embodiment of atrial overdrive pacing, the atrial escape interval is adjusted to decrease toward a programmed minimum value by measuring an A-A interval (defined as the time interval between the atrial sense and the preceding atrial sense or pace) when an atrial sense occurs and then computing an updated atrial escape interval based upon the measured A-A interval. When an atrial pace is delivered, on the other hand, the atrial escape interval is made to slowly increase so that the atrial pacing rate decays toward its programmed base value. FIGS. 4A and 4B show an exemplary implementation of an overdrive pacing system made up of a pair of filters 515 and 516 which may be implemented as software executed by the controller 10 (a.k.a. firmware) and/or with discrete components. Filter 515 is employed to compute the updated atrial escape interval when an atrial sense occurs, and filter 516 is used when an atrial pace is delivered. When an atrial sense occurs, the measured A-A interval is input to a recursive digital filter 515 whose output is the updated atrial escape interval. The filter 515 multiplies the measured A-A interval by a filter coefficient A and then adds the result to the previous value of the output (i.e., the present atrial escape interval) multiplied by a filter coefficient B. The operation of the filter is thus described by AEI n =X(AA n )+Y(AEI n−1 ), where X and Y are selected coefficients, AA n is the most recent A-A interval duration, and AEI n−1 is the previous value of the atrial escape interval. The filter thus causes the value of the atrial escape interval to move toward the present A-A interval multiplied by a scaling factor at a rate determined by the filter coefficients. When an atrial pace is delivered due to expiration of the atrial escape interval without an atrial sense, filter 516 multiplies the present atrial escape interval by a filter coefficient Z so that AEI n =Z(AEI n−1 ). To provide stable operation, the coefficient Z must be set to a value greater than 1. Filter 516 then causes the atrial escape interval to increase in an exponential manner with each pace as successive values of the escape interval are input to the filter up to a value corresponding to the base atrial escape interval. In order to overdrive the atria, the coefficients of filters 515 and 516 are selected so that the atrial escape interval decreases rapidly toward a value less than the present A-A interval when an atrial sense occurs and increases slowly toward a programmed base value when a pace is delivered.
[0000] 5. Initiation of AERP-Extension Pacing
[0026] The controller may be programmed to enter the AERP-extension mode for a specified time period either upon command from an external programmer, periodically or at other specified times during normal operation, or in response to sensed events. One particular situation where AERP-extension pacing may be especially beneficial is in the period following an atrial defibrillation shock. It has been found that the atria are in a supervulnerable period lasting approximately one minute immediately following an atrial defibrillation shock. During this time, the atrial effective refractory period is shortened from its value during the atrial fibrillation. This condition predisposes the patient to post-shock re-initiation of the atrial fibrillation, commonly referred to as early recurrence of atrial fibrillation or ERAF. To deal with this situation, the device can be programmed so that, upon detection of atrial fibrillation, an atrial defibrillation shock is delivered to terminate the fibrillation followed by AERP-extension pacing for a specified time period. The device may also be programmed to deliver AERP-extension pacing for a specified time following delivery of atrial anti-tachycardia pacing.
[0027] Although the invention has been described in conjunction with the foregoing specific embodiment, many alternatives, variations, and modifications will be apparent to those of ordinary skill in the art. Such alternatives, variations, and modifications are intended to fall within the scope of the following appended claims. | A device and method are presented for prolonging the atrial effective refractory period with pacing therapy. Such refractory period prolongation renders the atrial tissue less susceptible to the onset of atrial fibrillation. A particularly useful application is during the period after application of electrical therapy to the atria to terminate an episode of atrial fibrillation. | 0 |
RELATED APPLICATIONS
[0001] This application claims the benefit of provisional U.S. Patent Application Ser. No. 60/500,492, filed Sep. 5, 2003, and entitled “Interlocking Masonry Wall Block.”
FIELD OF THE INVENTION
[0002] This invention relates to a masonry block for stacking on other like-shaped blocks in a staggered, interlocking and offset manner to form a wall that is particularly well-suited for use as a vertical seating wall around patios, pool decks, walkways, and the like.
BACKGROUND OF THE INVENTION
[0003] A variety of masonry block designs have been developed for building vertical seating walls. Wall block designs require a mechanism for securing the blocks together to produce a stable wall structure. Conventional interlocking masonry wall blocks are heavy and difficult to handle. In addition, several different block shapes must be combined to form the straight and curved sections of a serpentine wall. The need remains for masonry wall blocks that are cost-efficient to manufacture and easily assembled into a stabile and durable wall.
SUMMARY OF THE INVENTION
[0004] Each block in an upper course of blocks is laid in a staggered manner relative to a lower course so that the upper block is placed atop two lower blocks. Single block units mate with like units to build straight walls, inside curves, outside curves and angle corners. Laterally adjacent blocks may be similarly aligned. Alternatively, laterally adjacent blocks may be inversely aligned so that the front wall of one block lies adjacent the rear wall of the adjacent block.
[0005] According to one aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The core has a width less than 1.25× the width of the projections. The projections are adapted for placement within the core of an underlying block in the retaining wall.
[0006] In one embodiment, the core is offset between the front and rear wall outer surfaces. In another embodiment, the core is centered between the front and rear wall outer surfaces.
[0007] In one embodiment, the first and second projections are offset between the front and rear wall inside surfaces. In another embodiment, the first and second projections are spaced equidistant between the front and rear wall inside surfaces.
[0008] According to another aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The projections are adapted for placement within the cavity of an underlying block in the retaining wall. At least one of the first and second side walls includes a score line between the cavity and the respective first or second projection that extends from the front wall outer surface to the rear wall outer surface.
[0009] In one embodiment, the core is offset between the front and rear wall outer surfaces. In another embodiment, the core is centered between the front and rear wall outer surfaces.
[0010] In one embodiment, the first and second projections are offset between the front and rear wall inside surfaces. In another embodiment, the first and second projections are spaced equidistant between the front and rear wall inside surfaces.
[0011] According another aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The projections are spaced equidistant between the front and rear wall inside surfaces and adapted for placement within the cavity of an underlying block in the retaining wall so as to provide essentially no setback dimension between the block and the underlying block.
[0012] In one embodiment, there is essentially no setback dimension when the first and second projections are placed within the cavity of the underlying block in an abutting relation to the front wall inside surface of the underlying block.
[0013] In another embodiment, there is essentially no setback dimension when the first and second projections are placed within the cavity of the underlying block in an abutting relation to the rear wall inside surface of the underlying block.
[0014] In one embodiment, the core is offset between the front and rear wall outer surfaces. In another embodiment, the core is centered between the front and rear wall outer surfaces.
[0015] In one embodiment, the first and second projections are spaced equidistant between the front and rear wall outside surfaces.
[0016] According to another aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls that extend from the front wall to the rear wall. The front wall has a length greater than the length of the rear wall such that the first and second side walls converge toward one another as they extend from the front wall toward the rear wall. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The first and second projections are adapted for placement within the cavity of an underlying block in the retaining wall. The front wall of the block is configured to lie adjacent the rear wall of a laterally adjacent block in the retaining wall such that the cavity of the block is positioned to receive the first projection of an overlying block in the retaining wall in an abutting relation to the inside surface of the front wall of the bock and the cavity of the laterally adjacent block is positioned to receive the second projection of the same overlying block in the retaining wall in an abutting relation to the inside surface of the rear wall of the laterally adjacent block.
[0017] In one embodiment, the front wall and the rear wall are of equal width.
[0018] A masonry wall block for forming a retaining wall comprising a body having a front wall, a rear wall, and first and second side walls that extend from the front wall to the rear wall. The front wall has a length greater than the length of the rear wall such that the first and second side walls converge toward one another as they extend from the front wall toward the rear wall. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The first and second projections are adapted for placement within the cavity of an underlying block in the retaining wall. The front wall of the block is configured to lie adjacent the rear wall of a laterally adjacent block in the retaining wall such that the cavity of the block is positioned to receive the first projection of an overlying block in the retaining wall in an abutting relation to the inside surface of the rear wall of the bock and the cavity of the laterally adjacent block is positioned to receive the second projection of the same overlying block in the retaining wall in an abutting relation to the inside surface of the front wall of the laterally adjacent block.
[0019] In one embodiment, the front wall and the rear wall are of equal width.
[0020] According to yet another aspect of the invention, a retaining wall comprises a lower tier of individual blocks, each block having a cavity, and an upper tier of individual blocks. Each block in the upper tier comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The projections are spaced equidistant between the front and rear wall inside surfaces and adapted for placement within the cavity of an underlying block in the retaining wall so as to provide essentially no setback dimension between the block and the underlying block.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a bottom perspective view of a masonry block unit.
[0022] FIG. 2 is a top perspective view of the block shown in FIG. 1 .
[0023] FIG. 3 is a bottom plan view of the block shown in FIG. 1 .
[0024] FIG. 4 is a top plan view of the block shown in FIG. 1 .
[0025] FIG. 5 is a front plan view of the block shown in FIG. 1 .
[0026] FIG. 6 is a side view of the block shown in FIG. 1 .
[0027] FIG. 7 is a perspective view of a masonry seating wall formed from like-shaped blocks.
[0028] FIG. 8 is a top plan view illustrating a series of laterally-adjacent blocks inversely aligned to form a straight wall.
[0029] FIG. 9 is a top plan view illustrating the arrangement of a series of inversely-aligned laterally-adjacent blocks to form an angular wall.
[0030] FIG. 10 is a top plan view illustrating an alternative arrangement of a series of inversely-aligned laterally-adjacent blocks to form an angular wall.
[0031] FIG. 11 is a top plan view illustrating an angular wall constructed by alternating courses arranged as in FIG. 9 with courses arranged as in FIG. 10 .
[0032] FIG. 12 is a top plan view illustrating the arrangement of a series of similarly aligned laterally-adjacent blocks to form a straight or linear wall.
[0033] FIG. 13 is a top plan view illustrating the arrangement of a series of similarly aligned laterally-adjacent blocks to form a curved wall.
[0034] FIG. 14 is a top plan view illustrating the arrangement of a series of similarly aligned laterally-adjacent blocks to form a wall having straight portions and curved portions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] An individual masonry block 10 for use in constructing vertical seating walls around patios, pool decks, walkways, etc. is shown in FIGS. 1-6 . The block 10 has a main body 12 having a front wall 14 having an outside surface 16 and an inside surface 18 , a rear wall 20 having an outside surface 22 and an inside surface 24 , and first and second side walls 26 each having an outside surface 28 and an inside surface 30 . The inside surfaces 18 / 24 / 30 of the walls 14 / 20 / 26 define an open core 32 .
[0036] The upper surfaces of walls 14 , 20 , and 26 define an upper surface 34 of the body 12 . The lower surfaces of walls 14 , 20 , and 26 define a lower surface 36 of the body 12 . The upper and lower surfaces 34 and 36 are generally parallel to each other. When laid in place on a horizontal supporting surface, the upper and lower surfaces 34 and 36 are horizontal as well.
[0037] The front wall 14 has a length L F and the rear wall 20 has a length L R . Each side wall 26 converges toward the other at an angle A as it extends toward the rear wall 20 such that L F >L R , thereby providing the block 10 a generally trapezoidal shape. The front and rear walls 14 and 20 are generally parallel (i.e., both walls 14 and 20 are of an essentially straight or linear configuration), and generally perpendicular to upper and lower surfaces 34 and 36 . It is contemplated, however, that either or both of front and rear walls 14 and 20 may be of a curvilinear configuration, e.g., convex, arcuate, or serpentine configuration (not shown). Front and rear walls 14 and 20 are desirably both finished (split, soft split or textured). The block 10 has a width W B .
[0038] Desirably, at least one score line 38 is provided. In a preferred embodiment, a pair of opposing score lines 38 are provided. In the illustrated embodiment, the score lines 38 take the form of a V-shaped grooves G. The score lines 38 are generally parallel and extend from the front wall 14 to the rear wall 20 . A block 10 may be split along a score line 38 to form an end block 40 presenting a flat end surface 42 , as will be explained in detail later (see FIGS. 9-11 ).
[0039] Two opposing integral lug projections 44 extend from the lower surface 36 of the block 10 . In the illustrated and preferred embodiment, a first projection 44 extends from the lower surface 36 of the first side wall 26 and the second projection 44 extends from the lower surface 36 of the second side wall 26 . Each projection 44 is desirably positioned between the score line 38 and the outside surface 28 of the respective side wall 26 . The projections 44 are generally rounded or convex, having a radius R L , a height H L , and a width W L . It is contemplated that the projections 44 may take on a variety of other configurations, e.g., rectangular or square, to accommodate specific needs. In a preferred embodiment, each lug projection 44 is generally centered equidistant between the front wall inside surface 18 and the rear wall inside surface 24 such that distance D1 and distance D2 are essentially equal.
[0040] The open interior or core 32 extends completely through the block 10 from the upper surface 34 to the lower surface 36 . The open core 32 does not present a trapezoidal shape as does the block body 12 , but instead has a generally elongated, rounded shape having a length L C , width W C and radius R C . Desirably, the width of the core 32 is only slightly larger than the width of the projection 44 , such that W C is only slightly greater than W L . This arrangement allows for easy placement of the projections 44 within the core 32 of an adjacent-tiered block 10 and provides a tolerance allowing for expansion, contraction, or settling movement of the blocks 10 . This arrangement also provides sufficient tolerance for orientating the blocks 10 in various configurations, e.g., curved walls, as will be described later. In addition, this arrangement permits minimal forward or reverse movement of the blocks 10 within the retaining wall, thus providing additional stability to the wall. For example, the core 32 may have a width W C that is less than twice the width of the projections W L (W C <2×W L ), and preferably W C is less than 1.25 times W L (W C =1.25×W L ). In a preferred embodiment, the core 32 has a width of 1½ inches and each lug projection 44 has a width of 1⅜ inch.
[0041] With reference to FIG. 3 , the core 32 is desirably slightly offset between the front and rear walls 14 and 20 . For example, in one embodiment, the rear wall 20 is of a slightly greater width than the width of the front wall 14 such that distance D3>distance D4. In this arrangement, there is no or zero setback when the projections 44 are placed in an abutting relation with the inside surface 24 of the rear wall 20 within the core 32 of a similarly-aligned adjacent-tiered block 10 . In an alternative embodiment, the front wall 14 is of a slightly greater width than the width of the rear wall 20 such that distance D4>distance D3. In this embodiment, there is no or zero setback when the projections 44 are placed in an abutting relation with the inside surface 18 of the front wall 14 within the core 32 of a similarly-aligned adjacent-tiered block.
[0042] In an alternative embodiment, the core 32 is not offset, i.e., the front and rear walls 14 and 20 are of equal width, such that D3=D4. In this embodiment, there is no or zero setback when the projections 44 are placed equidistant between the front and rear inside wall surfaces 18 and 24 within the core 32 of a similarly-aligned adjacent-tiered block 10 . In this case, it may be desirable to slightly offset the projections 44 with respect to the core 32 (i.e., such that D1≠D2) so as to provide zero offset when the projections 44 abut the front wall inside surface 18 or the rear wall inside surface 24 of an adjacent-tiered block 10 .
[0043] One of ordinary skill in the art should readily appreciate that the volume of the core 32 can vary, but is preferably maximized to decrease the weight and material cost of the block 10 without impairing the strength, integrity and manufacturability of the block 10 . Similarly, the actual shape and dimensions of the core 32 can vary, provided the core 32 maintains the ability to receive the lug-shaped projections 44 of another block 10 , as will be described later.
[0044] Table 1 lists dimensions for a representative embodiment:
TABLE 1 Length L F of front wall 12 inches Length L R of rear wall 9 inches Width W of block 7 inches Angle A 12° Lug height H L {fraction (5/16)} inch Lug width W L 1⅜ inch Radius of lug R L ¼ inch Length of core L C 6 inches Width of core W C 1½ inches Radius of core R c ¾ inch D1 ¾ inch D2 ¾ inch D3 3¾ inches D4 3¼ inches Groove G ⅛ inch
[0045] The block 10 configuration enables a fastening system that provides simple construction and automatic wall alignment. The like-shaped blocks 10 are sized and configured to be laterally aligned in an abutting side-by-side engagement, and vertically aligned in a staggered, stacked manner so that one block 10 rests atop two other blocks 10 .
[0046] When arranged in this manner, the blocks form a multi-tiered wall (W), such as the wall W shown in FIG. 7 . With reference to FIG. 8 , the wall W is typically constructed one tier or course at a time. Once a lower course 46 (represented in phantom lines in FIG. 8 ) is set in place, an upper course 48 (represented in solid lines in FIG. 8 ) is placed on top of it. The blocks 10 forming the lower course 46 form a generally horizontal platform upon which the upper course 48 can be stacked.
[0047] An interlocking fit is achieved between the like-shaped blocks 10 in adjacent upper and lower courses 48 and 46 . Each block 10 in the upper course 48 is laid in a staggered manner relative to the lower course 46 so that the upper block 10 is placed atop two lower blocks 10 . Each block 10 is also placed such that one of its lug projections 44 extends into and is received by the open core 32 of an adjacent block 10 in an adjacent course 46 or 48 . This interlock limits forward or backward movement of blocks 10 in one course 46 or 48 relative to the blocks 10 of an adjacent course 46 or 48 . This arrangement also limits sideways or lateral movement of blocks 10 in one course 46 or 48 relative to the blocks 10 of the adjacent course 46 or 48 .
[0048] The first course may be laid such that the lower surface 36 and projections 44 are positioned facing upward (i.e., with upper surface 34 facing downward). Upward positioning of the projections 44 may be desirable if the first course is to be laid on a hard or finished surface, e.g., on a patio or deck 50 , as shown in FIG. 7 . In this embodiment, the subsequent courses may all be similarly laid with the lower surface 36 and projections 44 facing upward, such that each projection 44 extends into and is received by the open core 32 of an adjacent upper block 10 . That is, the upper surface 34 of each block 10 in each stacked, upper course 48 is placed on and rests on the lower surfaces 36 of the blocks 10 in the lower course 46 upon which it is placed.
[0049] Alternatively, subsequent courses may all be laid with the projections 44 facing downward, such that each projection 44 extends into and is received by the open core 32 of an adjacent lower block 10 . That is, the lower surface 36 of each block 10 in each stacked, upper course 48 is placed on and rests on the upper surfaces 34 of the blocks 10 in the lower course 46 upon which it is placed. The final course is desirably laid with the projections 44 facing downward regardless of whether the previous courses were laid with the projections 44 facing upward or downward to present the flat or smooth upper surfaces 34 of the blocks 10 forming the top course, thereby eliminating the need to cut or otherwise remove the projections 44 from the blocks 10 forming the top course.
[0050] Alternatively, the first course may be laid with the lower surface 36 and projections 44 positioned facing downward (i.e., with upper surface 34 facing upward). Downward positioning of the projections 44 may be desirable if the first course is to be laid on soil or other surface in which the projections 44 may be extended to further anchor the first course blocks 10 . If the first course is laid with the projections 44 facing downward, the subsequent courses are preferably all laid with the projections 44 facing downward. This arrangement also presents the flat or smooth upper surfaces 34 of the blocks 10 forming the top course.
[0051] With reference again to FIG. 8 , in each course, adjacent like-shaped blocks 10 may be laterally inversely aligned so that the front wall 14 of one block 10 lies adjacent the rear wall 20 of the adjacent block 10 . The core 32 of a block 10 is positioned to receive the first projection 44 of an overlying block 10 and the laterally adjacent block 10 is positioned to receive the second projection 44 of the same overlying block 10 . The placement of the projections 44 and the core 32 with respect to the front and rear wall outside surfaces 22 and 28 can be varied to provide no offset dimension and to permit construction of an essentially straight or linear wall or wall portion W L , as shown in FIG. 8 .
[0052] When the core 32 is spaced essentially equidistant between the front and rear wall outside surfaces 22 and 28 , the core 32 of a block 10 is positioned to receive the first projection 44 of an overlying block 10 in the retaining wall W in an abutting relation to the inside surface 24 of the front wall 14 of the bock 10 and the core 32 of an inversely-aligned and laterally-adjacent block 10 is positioned to receive the second projection 44 of the same overlying block 10 in an abutting relation to the inside surface 24 of the rear wall 20 of the laterally adjacent block 10 . Alternatively, when the core 32 is spaced essentially equidistant between the front and rear wall outside surfaces 22 and 28 , the core 32 of the block 10 is positioned to receive the first projection 44 of an overlying block 10 in the retaining wall W in an abutting relation to the inside surface 24 of the rear wall 20 of the bock 10 and the core 32 of an inversely-aligned and laterally-adjacent block 10 is positioned to receive the second projection 44 of the same overlying block 10 in an abutting relation to the inside surface 18 of the front wall 14 of the laterally adjacent block 10 .
[0053] As seen in FIGS. 9-11 , laterally inversely-aligned blocks 10 may also be arranged to construct a wall W having an essentially 90° angle. Laterally-adjacent blocks 10 may be broken along a score line 38 (with broken away sections represented in phantom in FIGS. 9 and 10 ) to form an end block 40 presenting a flat side end surface 42 . FIG. 9 illustrates one arrangement (C1) of blocks 10 suitable for forming an angle. FIG. 10 illustrates another arrangement (C2) of blocks 10 suitable for forming an angle. Beginning with either a C1 or a C2 course, C1 and C2 courses can be alternated and staggered as shown in FIG. 11 (with the C1 course represented in solid lines and the C2 course represented in phantom lines) to construct an angular wall W of a desired configuration.
[0054] As shown in FIG. 12 , in each course 46 and 48 , like-shaped blocks 10 may also be laterally similarly or uniformly aligned so that the front wall 14 of one block 10 lies adjacent the front wall 14 of the adjacent block 10 . This arrangement permits the construction of an essentially straight or linear wall or wall portion W L in which the side walls 26 of laterally adjacent blocks 10 define an angle B, as FIG. 12 also shows.
[0055] To accommodate a variety of landscapes and individual design plans, it is often desirable to construct a wall W in which at least a portion is of a curved or arcuate configuration. As seen in FIGS. 13 and 14 , like-shaped blocks 10 may also be laterally similarly or uniformly aligned to form a curved wall portion W C by decreasing angle B. As illustrated in FIG. 13 , each side wall 26 of a block 10 can be placed so as to contact or abut along its entire length a side wall 26 of a laterally adjacent block 10 . In this arrangement, angle B=0° and the curved portion W C will have a minimum radius R 1 .
[0056] Alternatively, as illustrated in FIG. 14 , blocks 10 can be placed such that the side walls 26 of laterally adjacent blocks are not in contact along the entire length of the laterally adjacent side walls 26 . In this arrangement the curved portion W C will have a radius R 2 greater than the minimum radius R 1 , such that R 2 >R 1 . It will be readily apparent to one of skill in the art that angle B may be selected and varied so as to provide a desired degree of curvature.
[0057] Curved portions W C may be arranged in either a convex or a concave manner. The degree of curvature may also be selected to provide a low radius curve, a medium radius curve, or a high radius curve. In addition, the blocks 10 can be arranged to gradually or rapidly increase or decrease the radius of the curvature to accommodate a specific setting, landscape or purpose. It is contemplated that blocks 10 may be aligned to form a wall W having both straight portions and curved portions W L and W C (see FIG. 14 ).
[0058] With reference again to FIG. 7 , the top course of blocks 10 in the wall W is preferably capped by a series of cap stones 52 to cover the open cores 32 of the blocks 10 that form the top course or portion of the top course. The cap stones 52 may be of similar size and configuration to blocks 10 , but without a core 32 . Alternatively, the cap stones 52 may be of an alternative size and/or configuration otherwise adapted for placement over the top course. The cap stones 52 can be glued or otherwise adhered to the upper surface 34 of the top course of blocks 10 , e.g., by masonry adhesive. | Single masonry units mate with like units to build straight walls, inside curves, outside curves and most any angle corners and maintains finish on all exposed surfaces. The interlocking fastening system provides simple construction and automatic wall alignment. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/684,053 filed Aug. 16, 2012, which application is hereby incorporated by reference for all purposes in its entirety.
[0002] This application claims the benefit of U.S. Provisional Application No. 61/684,059 filed Aug. 16, 2012, which application is hereby incorporated by reference for all purposes in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] N/A
REFERENCE TO MICROFICHE APPENDIX
[0004] N/A
BACKGROUND OF THE DISCLOSURE
[0005] 1. Field of the Disclosure
[0006] This disclosure relates to apparatus and method for well production of fluids and gas.
[0007] 2. Description of the Related Art
[0008] In the production of wells and other product sumps, the effluent of the well may contain materials which are harmful to the operation of the production of desirable materials. An example of this is oil and gas wells. If these wells produce, they usually produce oil and gas and significant amounts of water. The water is not desirable and has to be hauled away in trucks or barges. It is not known how to suppress water as an effluent from the well. This suppression of water effluent might also avoid pollution and pressure loss in the well, which loss decreases the volume of oil and gas produced as the volume of water increases, ultimately making the well unprofitable.
[0009] As another illustration, it is not known how to suppress salts and other minerals as effluent from seawater producing water.
BRIEF SUMMARY OF THE DISCLOSURE
[0010] The apparatus is located in a well or other producer of liquids which may be used to produce a product. The product production may also involve the production of undesirable by-products, such as the production of a well that produces effluents of oil and gas with a harmful by-product of water. The apparatus is configured to reduce or eliminate the water in the product stream by preventing the harmful by-product from entering the product stream in whole or in part. To accomplish this, a downhole fluid gas directional compressor is inserted below an isolation packer abutting a casing. The isolation packer prevents fluid being in the annulus between the casing and the tubing from flowing to the surface with the desirable product with present production of undesirable fluid. The fluid is forced in the apparatus to flow into the downhole fluid gas directional compressor. The compressor then separates the undesirable product by having the undesirable product impeded from passing through the compressor while the oil and gas passes through the compressor. Thus, in an oil and gas well, the oil and gas will flow through the well annulus to the surface while the water in the well is caused to reenter the formation by the compressor of the apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a further understanding of the nature and objects of the present disclosure, reference should be made to the following drawings in which like parts are given like reference numerals and wherein:
[0012] FIG. 1 is a depiction of the installation of the Downhole Fluid Gas Directional Compressor mounted, in a well and showing the flow of oil gas and water passing through the compressor according to one embodiment of the present disclosure;
[0013] FIG. 2 is a side view of a Downhole Fluid Gas Directional Compressor;
[0014] FIG. 3 is an end view of a first end of the Downhole Fluid Gas Directional Compressor of FIG. 2 ;
[0015] FIG. 4 is an end view of a second end of the Downhole Fluid Gas Directional Compressor of FIG. 2 ;
[0016] FIG. 5 is a cross-sectional view of the Downhole Fluid Gas Directional Compressor taken along the section lines A-A of FIG, 2 ;
[0017] FIG. 6 is a top view of the device showing three bands or rings on the outside of the compressor 100 :
[0018] FIG. 7 is a partial view of a screen construction of the Downhole Fluid Gas Directional Compressor of FIG. 2 with the sand screen partially in place; and
[0019] FIG. 8 is a side view partly in phantom line of the stepped bars.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] FIG. 1 shows a downhole system 110 configured to exclude water from oil and gas stream flowing to the surface 104 . The exclusion device 110 comprises a gas directional compressor 200 mounted in a well bore 103 . The well bore 103 runs from the length of the well to the surface 104 . The well bore 103 has a well casing 102 which supports a well tubing string 106 . The lower end of the well tubing siring 106 is attached to an isolation packer 190 configured to provide pressure isolation and disposed between the casing 102 and the tubing 106 as would be understood by a person of ordinary skill in the art. The well tubing string 106 may also be used to suppress flow from the well 103 to the surface 104 . Oil 302 and gas 301 may flow through the well bore 103 and through the isolation packer connection 190 to tubing 106 and arriving at the surface 104 , which is well known in the art. However, for the present disclosure, the flow of the water 303 does not flow into well bore tubing 106 through the downhole device or compressor 200 . Instead the water 303 , after encountering the compressor 200 through a screen 240 , is reinjected by the compressor 200 back into the formation surrounding the casing 102 . The compressor 200 separates at least some of the water 303 from the oil 302 and gas 301 . The water 303 flows, for example, back through perforations 107 in the casing 102 to the formation. The compressor 200 is the primary part of the exclusion device 110 . In some embodiments, an optional second compressor 210 maybe disposed above or below compressor 200 and attached to well bore tubing 106 . In some embodiments, the compressor 200 may be disposed uphole, downhole, or level with the perforations 107 .
[0021] FIG. 2 shows an exemplary compressor 100 that may be used as compressor 200 or 210 , Compressor 100 may include a housing 105 . The screen 240 (or core frame) may be disposed in openings of the housing 105 and configured to allow fluids 301 , 302 , 303 to enter into the compressor 100 through openings 260 . The compressor 100 may be configured to attach to well bore tubing 106 at threaded connection points 160 . Attachment to the well bore tubing 106 may be facilitated by nuts 304 , 305 configured to mating with conventional downhole piping tools. Slot 170 may be configured to receive welding material in order for the screen 240 or its sub components ( FIG. 8 ) to be attached to the compressor 100 . As shown in FIG. 2 , the number of grooves 260 in the device 110 is another means of controlling the flow of oil and gas, as is the diameter of the device 110 .
[0022] FIG. 3 shows a nut 304 and threaded pipe 160 along the A-A. section lines of FIG. 2 . Similarly, FIG. 4 shows nut 305 and threaded pipe 160 from the opposite direction.
[0023] FIG. 5 shows the inner diameter 155 of the device 100 .
[0024] FIG. 6 shows the compressor 100 surrounded by rings or bands 280 disposed between the nuts 304 , 305 . The rings 280 may be attached (such as by welding or other suitable techniques known to person of ordinary skill in the art) on both ends of compressor 100 and in the middle. The rings 280 may also be attached outside either of the screen 240 and/or the wire bars 120 ( FIG. 7 ) and configured to protect the screen 240 and/or the wire bars 120 . Note that the bands 280 do not fully obstruct or do not obstruct the flow of fluids through the wire screen 240 .
[0025] Generally the pressure on the outside of the compressor 100 controls the How of oil and gas and other materials. As configured in FIG. 1 , the hydrostatic head in the well bore 103 may be 1000 feet. As the well bore length may be 4000 feet, the net hydrostatic head will be 3000 feet, and half of that pressure will be applied to the outside of the compressor 100 . Optional pressure relief valve 290 may be disposed on the bottom or lower end of compressor 100 . The pressure relief valve 290 may be configured to prevent or control excessive pressures from occurring inside the compressor 100 . Alternatively, a choke device may be used to regulate internal pressure of the compressor 100 .
[0026] FIG. 7 shows a series of bars 120 and wire 121 that may be formed, and form and surround the screen 240 in the compressor 100 . The bars 120 may be wrapped symmetrically on the compressor 100 and configured to bar entrance of water 303 into the interior of the compressor 100 . The bars 120 may be disposed at different angles to achieve different permeabilities by placing alternate layers perpendicular or at other angles to decrease porosity through the wire gaps 121 to change flow of the oil and gas through the wire gaps 121 . The wire bars 120 may be also be configured as a zero tolerance sand screen or mineral screen.
[0027] FIG. 8 shows a configuration for welding bars 220 to compressor 100 . Welds (not shown) are used to bond industrial bars 220 together for added strength and stability. Each layer of bars 220 is stepped with each bar 220 shorter than the previous bar 220 . Each bar 220 is stepped at each end to allow for the proper amount of weld to weld the bars 220 together. This bonds the ends of each layer together and ail ends of bars 220 to the core frame 240 for attaching of the bars 220 . The spacing between them is filled to the top of the slot 170 with weld to complete the attaching of the bars 220 . | An oil and gas downhole device is disclosed wherein the device separates the oil and gas from undesired water, which returns to the formation. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of Korean Patent Application No. 2003-72141, filed on Oct. 16, 2003, in the Korean Intellectual Property Office, the disclosure of which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to correcting an error in a restored signal and more particularly to restoring a radio frequency (RF) signal optically picked up from the optical disc.
DISCUSSION OF THE RELATED ART
[0003] Data stored in Compact Discs (CDs) are encoded using eight bit-to-fourteen bit modulation (hereinafter, referred to as “EFM”) and data stored in digital versatile discs (DVDs) are encoded using eight bit-to-sixteen bit modulation (hereinafter, referred to as “EFM+”). An EFM signal is formatted such that the same logic value does not consecutively occur more than a predetermined number of times. This is done, so as to remove direct current components during playback and facilitate clock recovery.
[0004] In the case of CDs, pits with information are serially arranged and tracks, in which the pits are arranged, are arranged concentrically with a track pitch of 1.6. The lengths of the pits and the spaces between the pits are classified into nine values, i.e., 3T through 11T, based on the widths of clock pulses. Here, the term ‘T’ represents a period of one clock pulse; and the terms 3T and 11T represent the period of three clock pulses and the period of eleven clock pulses, respectively.
[0005] It is difficult to manufacture optical discs having uniform surfaces due to material characteristics of the optical discs and inherent constraints present in optical disc manufacturing techniques. Also, a constant shape and size of a region of the surface of an optical disc, on which a light beam is projected, cannot be maintained due to mechanical imperfections of optical pickup devices. Hence, the wavelength of an RF signal optically picked up from an optical disc may fall outside a specified range, resulting in an error in the EFM signal.
[0006] To record more information on an optical disc, pits on the optical disc should have a high density. Hence, as a result, the interference between the adjacent pits increases noise in the RF signal, causing an increase in the error rate of EFM data. In particular, 3T, which appears most frequently, is most affected by an error due to noise arising from interference. As a result, pit length of 3T appears to have decreased due to interferences among adjacent pits, and thus 3T may be wrongly considered as 1T or 2T. In this case, the EFM demodulation cannot be performed properly, resulting in an error in data demodulated by EFM.
[0007] In a conventional apparatus that attempts to solve this problem, phase errors are measured at the positive edges of pulses of an EFM signal having lengths of less than 3T. Signal phases are compared at the positive edges. If it is determined that a loss of 1T occurs at the positive edge which shows the larger phase, and the measured phase error is corrected. In this case, to measure the phase error, the level of an optically picked up RF signal is converted into the phase error using an analog-to-digital converter (ADC). Alternately, a phase error between a normal clock signal and an EFM signal that results from modulation of the RF signal is measured using a signal with a frequency that is much higher than that of the normal clock signal.
[0008] FIG. 1 is a block diagram of a conventional restoration system for an optical disc.
[0009] Referring to FIG. 1 , the conventional restoration system includes a slice 110 , a clock recovery phase locked loop (clock recovery PLL) 120 , a latch circuit 130 , and a demodulator 140 . The slice 110 samples an RF signal that is optically picked up. The clock recovery PLL 120 receives a signal EFMI from the slice 110 and generates a channel clock signal PCLK. The latch circuit 130 receives the signal EFMI from the slice 110 and the channel clock signal PCLK from the clock recovery PLL 120 to output the signal EFMNRZI in synchronization with the channel clock signal PCLK. The demodulator 140 demodulates the signal EFMNRZI received from the latch circuit 130 .
[0010] For error correction, the conventional restoration system must include an ADC or else requires a signal with a higher frequency than a normal clock signal. However, it is not desirable for the restoration system to include an ADC, because a large board size would be required to accommodate the ADC. Also, it is not economical to provide a signal with a higher frequency than the normal clock signal from the outside of an integrated circuit (IC) chip or install a signal generator for such a signal in a board. Also, such a process makes the optical disc system complex and, in particular, is not suitable for high-speed operations. Hence, there is a need for a restoration system and method for restoring a signal for an optical disc.
SUMMARY OF THE INVENTION
[0011] At least one embodiment of the present invention provides a restoration system, which performs error correction by using a sliced signal and a channel clock signal, without using an ADC or a clock signal with a higher frequency than the channel clock signal.
[0012] An aspect of the present invention also provides a restoration method by which error correction is performed by using a sliced signal and a channel clock signal.
[0013] According to one aspect of the present invention, a restoration system is provided that optically picks up information from an optical disc and restores the information. The restoration system comprises a slice circuit, a phase locked loop, a latch circuit, a 3T correction circuit, and a demodulator. The slice samples a signal optically picked up from the optical disc. The phase locked loop receives a signal output from the slice and generates a channel clock signal. The latch circuit receives the signal output from the slice and the channel clock signal; and the latch circuit outputs the signal output from the slice in response to the channel clock signal. The 3T correction circuit receives the channel clock signal, the signal output from the slice, and the signal output from the latch circuit and outputs a signal in which 3T is corrected. The demodulator demodulates the signal output from the 3T correction circuit.
[0014] The 3T correction circuit includes an extension storage device, a length measuring device, a phase detector, and an extension determiner. The extension storage device stores the signal output from the latch circuit in a predetermined storage device in response to the channel clock signal of the PLL, outputs a storage state, and outputs stored data in response to a signal output from an extension determiner. The length measuring device receives the storage state from the extension storage device, detects a period (2T/1T) of a predetermine pulse of the storage state, measures periods of previous and next pulses respectively before and after the predetermined pulse signal, and outputs a current length of the predetermined pulse, a previous length of the previous pulse, and a next length of the next pulse according to a measurement of the periods. The phase detector measures a phase difference between the channel clock signal and the signal output from the slice.
[0015] The phase detector thereafter outputs, according to a measurement, a leading phase, which indicates a difference between the signal output from the slice and the channel clock signal when the predetermined pulse is enabled; a trail phase, which indicates a difference between the signal output from the slice; the channel clock signal when the next pulse is enabled; and a previous phase, which indicates a difference between the signal output from the slice and the channel clock signal when the previous pulse is enabled. The extension determiner receives the current length, the previous length, the next length, the leading phase, the trail phase, and the previous phase and determines a need for a correction and a direction of the correction.
[0016] The extension storage device includes a plurality of shift registers.
[0017] According to another aspect of the present invention, a restoration method is provided. The method restores a signal in which 3T is corrected by using a signal output from a slice that samples a signal optically picked up from an optical disc; a channel clock signal output from a phase locked loop that receives a signal output from the slice; and a signal output from a latch circuit that receives the signal output from the slice and the channel clock signal and outputs the signal output from the slice in synchronization with the channel clock signal.
[0018] The method includes detecting a current length of a current pulse of the signal output from the latch circuit; a previous length of a previous pulse immediately before the current pulse; and a next length of a next pulse immediately after the current pulse. Further, the method detects a leading phase, which indicates a difference between the channel clock signal and the signal output from the slice when the signal output from the slice is enabled; a trail phase, which indicates a difference between the signal output from the slice and the channel clock signal when the next pulse is enabled; and a previous phase, which indicates a difference between the signal output from the slice and the channel clock signal when the previous phase is enabled. Further, the method involves determining whether the current length is less than 2T; selecting a two directional correction or a non-correction if the current length is less than 2T; and selecting a forward correction or a backward correction if the current length is equal to 2T.
[0019] The selection of one of the two directional correction and non-correction includes determining whether the current length is equal to 1T; selecting the non-correction if the current length is not equal to 1T; selecting the non-correction when both the previous length and the next length are less than or equal to 3T; and selecting the two directional correction when both the previous length and the next length are greater than 3T, if the current length is equal to 1T.
[0020] The selection of one of non-correction, forward correction, and backward correction results into selecting the non-correction if both the next length and the previous length are less than or equal to 3T. The selection technique results into selecting the forward correction if the previous length is greater than 3T and the next length is less than or equal to 3T. Further, the selection technique results into selecting the backward correction if the previous length is less than or equal to 3T and the next length is greater than 3T. Further, the technique can select the forward correction if both the next phase and the trail phase have a first phase error or the previous phase has a second phase error, when both the previous length and the next length are greater than 3T. However, the backward correction is selected if both the next phase and the trail phase have the second phase error or the previous phase has the first phase error, when both the previous length and the next length are greater than 3T.
[0021] The first phase error indicates that the signal output from the slice is fast and the second phase error indicates that the signal output from the slice is slow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Preferred embodiments of the invention are described with reference to the accompanying drawings, of which:
[0023] FIG. 1 is a block diagram of a conventional restoration system for an optical disc;
[0024] FIG. 2 is a block diagram of a restoration system for an optical disc according to an exemplary embodiment of the present invention;
[0025] FIG. 3 is a block diagram of a 3T correction circuit of FIG. 2 ;
[0026] FIG. 4 is a timing diagram of internal signals of a 3T correction circuit of FIG. 3 ;
[0027] FIG. 5 is a timing diagram of internal signals of the 3T correction circuit of FIG. 3 when a leading phase LP is fast and a trail phase TP is fast;
[0028] FIG. 6 is a timing diagram of internal signals of the 3T correction circuit of FIG. 3 when a leading phase LP is slow and a trail phase TP is slow; and
[0029] FIG. 7 is a signal flowchart illustrating a determination procedure of an extension determiner of FIG. 3 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0030] The preferred embodiments of the present invention will be described with reference to the appended drawings.
[0031] FIG. 2 is a block diagram of a restoration system for an optical disc according to an exemplary embodiment of the present invention.
[0032] Referring to FIG. 2 , the restoration system for an optical disc includes a slice 210 , a PLL 220 , a latch circuit 230 , a 3T correction circuit 250 , and a demodulator 240 .
[0033] The slice 210 samples an analog signal RF that is optically picked up from an optical disc. The PLL 220 receives a signal EFMI from the slice 210 and generates a channel clock signal PCLK. The latch circuit 230 receives the signal EFMI from the slice 210 and the channel clock signal PCLK and outputs a signal EFMNRZI in synchronization with the channel clock signal PCLK. The 3T correction circuit 250 receives the signal EFMNRZI from the latch circuit 230 , the signal EFMI from the slice 210 , and the channel clock signal PCLK from the PLL 220 and outputs a signal EFMNRZI′ in which a 3T pit length is corrected. The demodulator 240 demodulates the signal EFMNRZI′ output from the 3T correction circuit 250 .
[0034] FIG. 3 is a block diagram of the 3T correction circuit 250 of FIG. 2 .
[0035] Referring to FIG. 3 , the 3T correction circuit 250 includes an extension storage device 251 , a length measuring device 253 , a phase detector 255 , and an extension determiner 257 .
[0036] The extension storage device 251 stores the signal EFMNRZI in a predetermined storage device (not shown) in response to the channel clock signal PLCK, outputs a storage state S of the predetermined storage device to the length measuring device 253 , and outputs stored data signal EFMNRZI in response to a signal D received from the extension determiner 257 . It is preferable that the predetermined storage device is implemented using a shift register.
[0037] The length measuring device 253 receives the storage state S from the extension storage device 251 , if it detects a 2T/1T pit length, measures the lengths of the pulse before and after the pulse measured at a pit length of 2T/1T, and outputs a current length CL, a previous length PL, and a next length NL based on the measurement.
[0038] The phase detector 255 measures a phase difference between the channel clock signal PLCK and the signal EFMI and outputs a leading phase LP, a trail phase TP, and a previous phase PP based on the measurement. The extension determiner 257 receives the current length CL, previous length PL, next length NL, lead phase LP, trail phase TP, and previous phase PP, determines the need for correction and the direction of correction, and outputs the signal D for executing correction to the extension storage device 251 .
[0039] The current length CL, previous length PL, next length NL, leading phase LP, trail phase TP, and previous phase PP will now be described with reference to FIG. 4 .
[0040] FIG. 4 is a timing diagram of internal signals of the 3T correction circuit 250 of FIG. 3 .
[0041] Referring to FIG. 4 , the phase detector 255 classifies a phase error between the output signal EFMI of the slice 210 and the channel clock signal PLCK into a leading phase error (LPE) and a trailing phase error (TPE) and classifies the LPE and the TPE as either fast or slow.
[0042] In other words, when the PLL 220 locks a low state of the channel clock signal PLCK at an edge of the signal EFMI, if the channel clock signal PLCK is at a logic high (‘1’) at an edge of the signal EFMI, then the signal EFMI is ahead of the channel clock signal PCLK and is expressed as fast. On the other hand, when the signal EFMI is behind the channel clock signal PCLK, the signal EFMI is expressed as slow. Thus, as illustrated in FIG. 4 , the previous phase PP is slow, the leading phase LP is fast, and the trial phase TP is slow.
[0043] Referring to FIG. 4 , the previous length PL is 4T, the current length CL is 2T, and the next length NL is greater than or equal to 3T. Since the CL is equal to 2T, the signal EFMNRZI, which is output from the latch circuit 230 in response to the signal EFMI and the channel clock signal PLCK, has an error. The error occurs when the length of the signal EFMI is less than 3T and the length of the signal EFMI corresponding to the channel clock signal PLCK, i.e., corresponding to P 4 through P 6 , is greater than 2T but smaller than 3T. Here, T denotes the period of a pulse of the channel clock signal PLCK. If the extension determiner 257 determines that an error needs to be corrected considering a predetermined condition (which will be described below), the error is corrected through either forward extension, backward extension, or both directional extension.
[0044] FIG. 5 is a timing diagram of the internal signals of the 3T correction circuit 250 (shown in FIG. 3 ), when the leading phase LP is fast and the trail phase TP is fast. FIG. 6 is a timing diagram of the internal signals of the 3T correction circuit 250 of FIG. 3 when the leading phase LP is slow and the trail phase TP is slow.
[0045] Referring to FIGS. 5 and 6 , error rates can be compared according to logic states of the channel clock signal PLCK at both edges of the signal EFMI. It will be assumed for the sake of illustration that both edges are reduced when 3T is reduced to 2T, two cases should be considered. A first case being F 1 in which a leading edge of the signal EFMI occurs before a rising edge of the channel clock signal PCLK; and a second case being B 1 in which a trailing edge of the signal EFMI occurs before a rising edge of the channel clock signal PLCK.
[0046] Referring to FIG. 5 , when the leading phase LP and the trail phase TP are fast, if 1T is reduced in the forward direction, a phase error ranging from 0.5T to 1T occurs in the case F 1 . If 1T is reduced in the backward direction, a phase error ranging from 1T to 1.5T occurs in the case B 1 . Thus, the probability of the occurrence of the error in the case F 1 is greater than the error in the case B 1 . Hence, a forward extension is used for error correction.
[0047] Referring to FIG. 6 , when both the LP and the TP are slow, if 1T is reduced in the backward direction, a phase error of 0.5T to 1T occurs in a case B 2 . If 1T is reduced in the forward direction, a phase error of 1T to 1.5T occurs in a case F 2 . Thus, it is determined that the error in the case B 2 is higher than the error in the case F 2 . Thus, a backward extension is used for error correction.
[0048] In FIGS. 5 and 6 , both the LP and the TP are fast or slow. However, when the LP and the TP have different values, if the PP is slow, there is a high probability that the leading edge of the signal EFMI occurs before the rising edge of the channel clock signal PLCK. On the other hand, if the PP is fast, there is a high probability that the trailing edge of the signal EMI occurs before the rising edge of the channel clock signal PLCK. Thus, a forward extension and a backward extension are used respectively for the two cases.
[0049] FIG. 7 is a signal flowchart illustrating a determination procedure of the extension determiner 257 of FIG. 3 .
[0050] Referring to FIG. 7 , the determination procedure of the extension determiner 257 can be classified into a detection step (not shown), a first determination step 710 , a second determination step 720 , a third determination step 730 , non-correction 740 , two directional extension correction 750 , forward extension correction 760 , and backward extension correction 770 .
[0051] The detection step includes detecting a current length CL during a predetermined period of the signal EFMNRZI, a previous length PL of the pulse immediately before a pulse having the current length CL; a next length NL of the pulse immediately after the pulse having the current length CL; a lending phase LP, which indicates an error between the signal EFMI and the current clock signal PLCK when the signal EFMNRZI is enabled; a trail phase TP, which indicates an error between the signal EFMI and the channel clock signal PLCK when the pulse immediately after the pulse having the current length CL is enabled; a previous phase PP, which indicates an error between the signal EFMI; and the channel clock signal PLCK when the pulse immediately after the pulse having the current length CL is enabled.
[0052] In the first determination 710 , it is determined whether the current length CL is less than 2T. If the current length CL is 3T, a normal operation is performed and error correction is not required. Error correction is considered only when the current length CL is less than 3T.
[0053] In second determination step 720 , if the current length CL is not equal to 1T, no correction is selected (sub-determination step 721 ). If the current length CL is equal to 1T, and further if both the next length NL and the previous length PL are greater than 3T, then the two directional correction is selected. But if one of the next length NL and the previous length PL is less than or equal to 3T, no correction is selected (sub-determination step 723 ).
[0054] In third determination step 730 , the current length CL is equal to 2T. If both the next length NL and the previous length PL are less than or equal to 3T ( 731 ), no correction is selected ( 740 ). If the previous length PL is greater than 3T and the next length NL is less than or equal to 3T ( 732 ), a forward extension is selected ( 760 ). If the previous length PL is less than or equal to 3T and the next length NL is greater than 3T ( 733 ), a backward extension is selected ( 770 ).
[0055] When both the previous length PL and the next length NL are greater than 3T, if the both leading phase LP and the trail phase TP have a first phase error ( 734 ) or the PLL has a second phase error ( 736 ), a forward extension is selected ( 760 ). However, if both the leading phase LP and the trail phase TP have the second phase error ( 735 ) or the previous phase PP has the first phase error ( 736 ), a backward extension is selected ( 770 ).
[0056] It is preferable that the first phase error indicates that the signal EFMI is fast and the second phase error indicates that the channel clock signal PCLK is slow.
[0057] Those skilled in the art will appreciate that the block diagram of FIG. 3 and the signal flowchart of FIG. 7 are shown as only examples for illustration and understanding purposes, and may vary under different conditions.
[0058] As described above, the restoration system and method for an optical disc according to at least one embodiment of the present invention performs error correction using a sliced signal (EFMI) and a channel clock signal (PLCK) commonly used in a system, without using an ADC or a clock signal having a higher frequency than the channel clock signal. This results in achieving improved reliability of restoration in an optical disc system.
[0059] While the present invention has been particularly shown and described with reference to an exemplary embodiment thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents. | Provided are a restoration system and method for an optical disc, by which a radio frequency signal optically picked up from an optical disc is restored. The restoration system includes a slice, a phase locked loop, a latch circuit, a 3T correction circuit, and a demodulator. In particular, the 3T correction circuit includes an extension storage device, a length measuring device, a phase detector, and an extension determiner and corrects data output from the extension storage device. In the restoration method, data required for determining the need for correction and the direction of correction is detected and a plurality of steps for selecting non-correction, two directional correction, forward correction, and backward correction are performed, thereby correcting the high radio frequency signal according to conditions of the high radio frequency signal. It is preferable that the restoration system operates according to the restoration method. | 6 |
BACKGROUND OF THE INVENTION
The present invention concerns the automatic sewing machine sector, specifically those machines featuring two needles that are fitted beside one another and at the same height, made to move syncronously and in conjunction with one another in the vertical plane, to form a stitch with a single looper.
DESCRIPTION OF THE PRIOR ART
It is known that, by making the needles change over positions, one taking up the position previously occupied by the other, and vice versa, one can obtain special types of particularly interesting stitches, such as are, for example, used in sewing of a solely ornamental nature.
By carrying out suitable adjustments affecting the speed with which these needles change over positions, by, for example, coupling the means controlling the sewing machine to a computerised unit that faithfully follows through suitable programmes, any type of sewing may be carried out, even if featuring a sequence of different stitches.
To achieve the above in a sewing machine using a single looper, the orientation of each needle must remain unchanged in both the two positions occupied; otherwise it would not be possible to effect the stages in which needle and looper operate in conjunction to form the stitch required.
SUMMARY OF THE INVENTION
The object of the invention is to propose a device which enables two automatic sewing machine needles located beside one another to be driven synchronously in the vertical plane, in addition enabling the aforesaid needles to change over positions without their orientation in relation to the common looper undergoing any change.
A further object of the invention is to propose a device achieving the above with an easily produced and highly reliable technical solution, able to be operated by means that can be coupled to a computerised unit.
The said objects are obtained by means of a device for operating and orientating a pair of automatic sewing machine needles, in which each of the needles of this said pair are locked at one end to the same number of equal vertical rods, located beside one another and at the same height, characterised by the fact that it comprises; a cylindrical element that is able to move in the vertical plane, within which the aforementioned rods are located symetrically in relation to the axis of the said cylindrical element, projecting from it at both heads and supported by it in such a manner as to be able to turn, means, that are an integral part of the load-bearing structure of the said machine, being provided to guide the vertical movement of the said cylindrical element; means for driving the said cylindrical element with a vertical outwards and return movement; a sleeve, supported by the said structure such that it is able to move, to which the upper central portion of the cylindrical element is coupled, the said cylindrical element projecting beyond the sleeve and able to slide along its axis in relation to the sleeve; means for driving the said sleeve round by a half turn in a preset direction and, subsequently, by a half turn in the opposite direction to the previous one; transverse means, connected to the upper ends of the said rods, designed to prevent the cylindrical element from sliding out of the sleeve, and to keep the orientation of the said road unaltered when they change over positions as a result of the half turn rotation of the sleeve/cylindrical element assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics of the invention that have not emerged from the above, are emphasised hereinafter with specific reference to the drawings enclosed, in which:
FIG. 1 shows an axial vertical cross section of the device shown from the side with certain parts omitted so that others may be shown more effectively;
FIG. 2 shows the device seen from above;
FIGS. 3a, 3b and 3c show the same view as seen FIG. 2, but on a larger scale, with the transverse means, designed to keep the orientation of the needles unchanged, in the two extreme operating positions, as well as in an intermediate position between these two configurations;
FIG. 4 is an enlarged view of the cross-section IV--IV of FIG. 1, in which the two extreme operating positions taken up by the needle mounting are shown by continuous and broken lines respectively.
FIG. 5 shows an enlarged view of the cross-section V--V of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to these figures, 1 indicates a sleeve supported by the load-bearing structure 2 of an automatic (leather) sewing machine so that it is able to turn.
The sleeve features a pinion 3 on the outside of its upper portion, which engages with a rack 4 that is an integral part of the rod 5 of a pneumatic jack, not illustrated.
The upper central portion of a cylindrical element 6, able to move vertically, is coupled to the sleeve; the said coupling, effected using known means 27 (e.g.: a key), enables the element 6 to slide along its axis in relation to the sleeve.
Sleeve 1 and guide means 7, an integral part of structure 2, both serve to guide the vertical movement of cylindrical element.
The vertical movement of the cylindrical element is effected using known means 8, acting upon a portion of the latter which always remains outside the sleeve.
The cylindrical element 6 features two longitudinal passing through-holes that are located beside one another and positioned so that they are bilateral to the axis of the element, and thus with their relevant axes running along the same vertical plane as the axis of the said vertical element 6. Two equal vertical rods, 9a and 9b, are located inside these holes and project from both heads of the element 6. The lower ends of the said rods are fitted with corresponding needles 10a and 10b, by means of the same number of mountings 11a and 11b.
The upper ends of the rods 9a and 9b are connected to corresponding transverse means 12a and 12b, which serve to orientate the rods and thus the needles, as will be explained below.
Mountings 11a and 11b strike against the lower head of element 6, whilst the upper head of the latter acts as a stop against which strike means 12a and 12b, such that rods 9a and 9b are supported by the cylindrical element 6 in such a way as to be able to turn.
The said transverse means 12a and 12b are of sufficient size to be struck by the upper head of sleeve 1; this prevents the cylindrical element 6 from sliding out of the latter.
The said transverse means 12a and 12b have the same shape.
They each comprise a plate 13 through which a hole 14 passes; the edge of the plate features a curved protuberance 15 corresponding to the latter, with the concave surface facing outwards, the shape of which is defined by a half circumference that is coaxial with hole 14.
The said protuberance 15 follows on to the surface of a recess 16, with the concave surface facing inwards, the shape of which is defined by a half circumference the radius of which is greater than the radius of the previous half circumference.
The holes 14 of the two plates 13 of the relevant means 12a and 12b, receive the upper ends of rods 9a and 9b respectively; suitable locking means, not illustrated, hold the rods to the relevant plates: plates 13 are consequently prependicular to the relevant rods.
Each plate 13 has, as an integral part of the head adjacent to recess 16, a spigot 17, the head of which features two cylindrical crowns 18; it should be emphasised that the centres of curvature of crowns 18, and the centres of the curved surfaces of the said protuberance 15 and recess 16 lie in the midplane "α" of spigot 17.
The crowns 18 are placed between and in contact with two vertical guide surfaces 19a and 19b forming a vertical groove 19 produced as a unit 20 forming an integral part of the structure 2; the height of the said groove 19 exceeds the maximum travel of the stroke of cylindrical element 6, whilst its width is greater than the distance between the axes of rods 9a and 9b.
It should be emphasised that the distance between the axes of rods 9a and 9b is more than double the radius of the curved surface of protuberance 15; it should also be emphasised that means 12a is keyed to rod 9a so that its relevant protuberance faces side A, whilst the other means 12b is keyed to rod 9b so that its relevant protuberance faces side B opposite side A.
The two needles 9a and 9b work in conjunction with a single looper which is a sewing hooked needle that cooperates with the needle of a sewing machine (not illustrated insofar as of known type), located below surface 21.
A first working configuration of needles 10a and 10b is indicated as K1, in which mountings 11a and 11b assume the positions shown by the continuous lines in FIG. 4. In this configuration, the transverse means 12a and 12b for orientating the rods 9a and 9b (and thus the needles) are positioned as shown in FIG. 3a, that is to say with the protuberance 15 of one means freely inserted in the recess 16 of the other means, and vice versa; it should be emphasised that, in the above mentioned configuration K1, the axes of both rods 9a and 9b lie in the aforementioned plane "α", whilst the pairs of crowns 18 are at the minimum distance from one another: in other words, the aforesaid planes "α", relating to the spigots 17 of plates 13, coincide.
The second working configuration of the needles, indicated by K2, is obtained by making sleeve 1 turn anti-clockwise in direction Z1, by means of rack 4 driven by the pneumatic jack; this causes the tubular element 6 to rotate in the same direction, and the axes of rods 9a and 9b to turn through a half circumference in relation tto the axis of element 6.
The crowns 18 enable the spigots 17 of the relevant means 12a and 12b to be angled in relation to the midplane "β" of the corresponding groove 19, whilst, at the same time, the said crowns "slide" towards the inside of the relevant grooves 19; since rods 9a and 9b are held by the plates 13 of the corresponding means 12a and 12b, and the cylindrical element 6, a relative turning movement is effected.
At the end of each half turn in direction Z1, means 12a and 12b are positioned as shown in FIG. 3c; the axes of rods 9a and 9b once again lie in the two planes "α" which coincide once again, but their new positions (configuration K2) represent a change over from one to the other of their previous positions (configuration K1); it should be noted that the pairs of crowns 18 are at the maximum distance from one another.
As has been said, the axes of rods 9a and 9b lie in planes "α", coinciding with the said planes "β", in configuration K2 as well; this, together with the fact that the said rods are locked as an integral part to means 12a and 12b, enables the rods and thus the relevent needles to maintain the same orientation as they had in the first configuration K1.
This may is also be shown by the positions assumed by the needle mountings 11a and 11b; as illustrated by the broken lines in FIG. 4; the said figure clearly shows that the mountings change over positions from one configuration to the other, whilst maintaining the same orientation of the mountings themselves in both configurations.
The clockwise rotation of sleeve 1 by a half turn in direction Z2, returns the needles to the first configuration K1 once again.
The needles 10a and 10b effect the stitch in conjunction with the said crochet in both configurations K1 and K2; this has been neither illustrated nor described, the process being well known.
The above presupposes the synchronous movement of the needles, which is, as stated, effected by moving the tubular element 6 vertically using means 8, the oscillation of the former being permitted and at the same time guided by sleeve 1.
During the oscillation of the cylindrical element 6, the orientation of rods 9a and 9b, and thus of needles 10a and 10b, undergoes on change whatsoever due to the fact that sleeve 1 is prevented from rotating by the rack 4, and because means 12a and 12b keep the position assumed in the said configurations K1 and K2, this being made impossible by the guiding aation effected on the relevent crowns 18 by the vertical surfaces 19a and 19b of grooves 19; in other words, the coincidence of planes "α" and "β" is maintained in the said configurations K1 and K2.
The device enables two needles located beside one another to be driven synchronously, in addition enabling them to change over positions without their orientation being subjected to any variation, as is essential for them to be able to operate in conjunction with the crochet.
The device does not alter the orientation of the needles as determined by means 12a and 12b during the formation of the stitch.
The device is designed in such a way as to enable its operation in conjunction with a computerised unit; indeed the rack 4 is operated by a pneumatic jack (full on or off only) and the cylindrical element 6 is operated by a connecting rod system (means 8): it is obvious that these operating means can be interfaced to the computer without difficulty.
It is to be understood that the description supplied herein is solely an unlimited example, such that any possible variations in construction details will not affect the protective framework afforded to the invention as described above and claimed hereinafter. | A device for operating and orientating a pair of automatic sewing machine needles have two needles which are locked to the lower ends of two equal rods, located beside one another in the vertical plane. These needles change over position during stitching without requiring reorientation of the needles themselves. The device has a cylindrical element movable in the vertical plane, which has the needles and rods therein. The device also includes a sleeve and guides for guiding the vertical movement of the cylinder, with driving means for driving the sleeve and cylinder such that the orientation of the rods is unaltered when they change over position. This enables the needles to operate in conjunction with the looper of an automatic sewing machine to which the device is fitted. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2013/065466 filed Jul. 23, 2013, and claims the benefit thereof. The International Application claims the benefit of European Application No. EP12178221 filed Jul. 27, 2012. All of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to a low-pressure turbine comprising a first flow and a second flow and also a rotor and an inner housing arranged around the rotor and an outer housing arranged around the inner housing. The invention also relates to a method for operating a low-pressure partial turbine, the low-pressure partial turbine having a double-flow configuration.
BACKGROUND OF INVENTION
[0003] Steam turbines are usually divided into partial turbines. Thus, by way of example, a steam turbine used in local power supply is divided into a high-pressure partial turbine, an intermediate-pressure partial turbine and a low-pressure partial turbine. Each of these individual partial turbines mentioned above is accommodated in each case in an individual housing. Moreover, designs in which the high-pressure part and the intermediate-pressure part are accommodated in a common housing are known. Designs in which the intermediate-pressure part and the low-pressure part are arranged in a common housing are similarly known. An axial arrangement of the individual partial turbines in succession requires a comparatively large amount of installation space.
[0004] Since, for reasons of thermodynamics, the pressure and the temperature of the steam decrease from the high-pressure partial turbine to the low-pressure partial turbine, and as a result the volume increases greatly, in some cases a plurality of partial turbines are used. Moreover, the low-pressure partial turbines generally have a two-flow configuration. This means that the inflowing steam flows away both in one direction and also axially in the opposite direction. Low-pressure partial turbines are configured in such a manner that the exhaust steam in one flow and the exhaust steam in the second flow are carried away laterally. This is also known under the term Single Side Exhaust or Double Side Exhaust. A further embodiment provides that the low-pressure exhaust steam is carried away downward (what is termed Down Exhaust). This generally leads to an increased space requirement, since low-pressure partial turbines configured in this way have to be constructed either with a great width or with a great height. In particular, in the case of a Single Side Exhaust assembly, the pipe system is concentrated on one side, and might therefore lead to problems in terms of space. It would be desirable to have a narrow machine housing, in which the partial turbines can be arranged. Moreover, it is desirable to be able to implement a well-structured pipe system.
SUMMARY OF INVENTION
[0005] It is an object of the invention to specify a low-pressure partial turbine which requires relatively little space.
[0006] This object is achieved by a low-pressure partial turbine as claimed in the independent claim.
[0007] Advantageous developments are specified in the dependent claims.
[0008] An embodiment of the invention proceeds from the aspect that guidance of the low-pressure exhaust steam laterally or downward results in a high space requirement, and this can be eliminated by guiding the low-pressure exhaust steam in such a manner that it is carried away axially. To this end, it is proposed according to an embodiment of the invention to design the outer housing in such a manner that the exhaust steam chamber of the second flow is designed in such a manner that the steam is deflected in the same direction as the exhaust steam of the first flow. This means that the low-pressure exhaust steam of the second flow is deflected in the direction of the low-pressure exhaust steam of the first flow.
[0009] Advantageously, an annular space is thus formed between the inner housing and the outer housing, a low-pressure exhaust steam of the second flow flowing through said annular chamber and mixing with the low-pressure exhaust steam of the first flow on the output side.
[0010] An alternative embodiment would be a box-like construction of the inner housing outer wall, such that the inner housing could be positioned on the base in the thus formed chamber.
[0011] It is thus proposed according to an aspect of the invention to design a new outer housing for a two-flow low-pressure partial turbine which makes an axial discharge flow possible. The machine housing costs can thereby be reduced. Moreover, it is thereby possible to harmonize the basic power plants. Accordingly, considerable cost savings are possible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Aspects of the invention will be explained in more detail on the basis of an exemplary embodiment.
[0013] The FIGURE shows a schematic cross-sectional view of a low pressure partial turbine.
DETAILED DESCRIPTION OF INVENTION
[0014] The FIGURE shows a low-pressure partial turbine 1 , which has a two-flow configuration. This means that the low-pressure partial turbine 1 has a first flow 2 and a second flow 3 . Live steam flows into the low-pressure partial turbine 1 via an admission connector 4 . A flow path 8 is formed between a rotor 6 mounted rotatably about an axis of rotation 5 and an inner housing 7 arranged around the rotor 6 .
[0015] An outer housing 9 is arranged around the inner housing 7 . The rotor 6 is formed with individual rotor blades 10 . For the sake of clarity, only one rotor blade is provided with the reference sign 10 . Guide vanes 11 arranged on the inner housing 7 are arranged between the individual rotor blade stages. For reasons of clarity, only one guide vane is provided with the reference sign 11 .
[0016] Live steam flows in via the admission connector 4 and is expanded in the first flow 2 to the right, as seen in the plane of the drawing, and in the second flow 3 to the left, as seen in the plane of the drawing. The steam is expanded in the flow path 8 and is cooled in the process. After the last rotor blade 10 and guide vane 11 , the low-pressure exhaust steam 12 is deflected in the second flow 3 through the inner housing 7 . For this purpose, the outer housing 9 has deflection elements 13 , which deflect the steam again in the axial direction to the first flow 2 . An annular space 14 , through which the low-pressure exhaust steam 12 of the second flow 3 flows, is formed between the outer housing 9 and the inner housing 7 . The low-pressure exhaust steam 16 of the first flow 2 is mixed with the low-pressure exhaust steam of the second flow 12 in a mixing zone 15 . In this respect, it has to be ensured that the velocity of the low-pressure exhaust steam 16 of the first flow 2 is substantially the same as the velocity of the low-pressure exhaust steam 12 of the second flow 3 in the mixing zone 15 .
[0017] Then, the steam mixed from the low-pressure exhaust steam 16 of the first flow 2 and the low-pressure exhaust steam 12 of the second flow 3 flows into an exhaust steam chamber 17 and, after this exhaust steam chamber 17 , to the condenser (not shown in more detail). A base for a bearing 18 , on which the rotor 6 is mounted, is arranged in the exhaust steam chamber 17 . The site of the bearing 18 can be arranged in the steam chamber or, in alternative embodiments, can be positioned as a separate encapsulated base outside the steam chamber.
[0018] The low-pressure partial turbine ( 1 ) has a double-flow configuration and the exhaust steam from the first flow ( 2 ) is deflected in the direction of the exhaust steam of the second flow ( 3 ). The direction of the exhaust steam from the first flow ( 2 ) and the direction of the exhaust steam from the second flow ( 3 ) are oriented substantially parallel to the axis of rotation ( 5 ). | A double-flow low-pressure partial turbine is provided herein, wherein the exhaust steam of the first flow and the exhaust steam of the second flow are deflected in a common direction within the outer housing and thus axial outlet flow occurs. | 5 |
FIELD OF THE INVENTION
This invention relates to actuators for power transmissions and drive systems and more particularly, to a pivotable actuator for changing the condition of mechanical power transmissions and drive systems between power conditions such as neutral, forward, reverse, and/or braked states. In one embodiment, the actuator shifts a drive system from an engaged condition to a neutral condition and then to a braked condition.
BACKGROUND OF THE INVENTION
Prior art mechanical power transmissions and drive systems typically incorporate a clutch mechanism for transmitting power between power transmitting, rotary shafts. These prior art systems have limited applications because of their inability to easily shift between different conditions. When used with machines, such as power lawn mowers, it is particularly desirable for the operator to easily shift between the various operating conditions such as forward, neutral, and reverse in an easy, quick, and precise manner. Also, considerable effort to improve the braking system is being expended by manufacturers of the small machines discussed herein. For reasons of economy, the low power systems associated with riding and walk behind lawn mowers and the like, typically use mechanical actuators to engage and disengage the power source from the power drive system, as well as to reverse direction of the output shaft from the transmission. However, these mechanical actuators are somewhat complicated to operate. Since these relatively small machines are operated by a wide range of people, including many with little or no experience in operating machines, a safe, easy to operate and relatively inexpensive actuating system is extremely important.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved actuator for power transmissions and drive systems which obviates the problems and limitations of the prior art systems.
It is another object of the present invention to provide an improved, pivotable actuator for power transmissions and drive systems which is easily shifted to change the operating conditions.
It is still another object of the present invention to provide an improved actuator for power transmissions and drive systems which can quickly and easily shift between drive, neutral and reverse conditions.
It is yet another object of the present invention to provide an improved actuator for power transmissions and drive systems which can easily shift between an engaged, a neutral and a disengaged braked condition while avoiding simultaneous actuation thereof.
It is still further another object of the present invention to provide an improved actuator for power transmissions and drive systems which is easy to assemble and relatively inexpensive to manufacture while being sturdy enough to handle rough treatment by inexperienced equipment operators.
In accordance with the invention, a power drive system comprises a first rotary shaft having an actuation mechanism such as a clutch engagedly mounted therearound and an actuator for engaging and disengaging the actuation mechanism. A bearing device is disposed about the shaft and abutted against the actuator. A shift mechanism is disposed directly or indirectly against the bearing device for movement whereby the bearing device positions the actuator between a neutral position wherein the mechanism is disengaged and an operating position wherein the mechanism is engaged. The actual preferred pivoting function can be caused by the preferred rotary shafts with flats (which are easy to make, use, and seal once installed) or an alternate mechanism such as levers, cables, push rods or other force passing system, either singly or in multiples. Multiple actuation mechanisms can be actuated by using series or parallel mounted systems.
Preferably, the bearing device of the power drive system comprises an angular thrust ball bearing assembly, including concentric inner and outer bearing races with a plurality of ball bearings therebetween. The two races are non-symmetrical in cross section having a raised portion on one lateral side in order to efficiently transfer the actuation forces angularly between the races through the ball bearings. The inner bearing race is mounted surrounding the first rotary shaft. One race, preferably the outer race, is moved by the shift mechanism to position the actuator between the neutral and operating positions whereby the actuation mechanism is either engaged or disengaged via the other bearing race, preferably the inner race. This use of a ball bearing is preferred due to low cost and simplicity as well as a possible dual shaft support and activation function for the bearing. Also, there can be a single inventory of bearings. Alternately, axial thrust bearings, roller bearings, or other types of bearings could be utilized to transfer the described axial movement between stationary and rotating parts.
Further in accordance with one embodiment of the invention, a power transmission comprises two neighboring axially aligned rotary shafts and two actuation mechanisms. A first rotary shaft has a first clutch mechanism mounted therearound. A first clutch actuator, in cooperative relationship with a first clutch mechanism, engages and disengages the first clutch mechanism. A drive gear mechanism, mounted to the second shaft, is drivingly interconnected with the first clutch actuator for transmitting rotary power in one direction to the second rotary shaft whenever the first clutch actuator is engaged with the first clutch mechanism. A second rotary shaft, spaced from the first rotatable shaft, has a second clutch mechanism mounted therearound which is in cooperative relationship with a second clutch mechanism for engaging and disengaging the second clutch mechanism. An idler gear device interconnects the first rotary shaft to the second clutch actuator for transmitting rotary power in the other forward rotary direction from the first rotary shaft to the second rotary shaft whenever the second clutch actuator is engaged with the second clutch mechanism.
A shift mechanism is interconnected with the first and second clutch actuators. The shift mechanism has a neutral position for rotary movement of the first shaft without rotary movement of the second shaft, a forward position for rotary movement of the second shaft in one direction and a reverse position for rotary movement of the second shaft in the other direction. The shift mechanism includes a first bearing device of the transmission that abuts against the first clutch actuator for rotatably supporting the clutch actuator and a second bearing device that abuts against and rotatably supports the second clutch actuator. The first bearing device comprises a first ball bearing assembly, including concentric inner and outer bearing races with a plurality of ball bearings therebetween. The inner race is mounted about the first rotary shaft and the outer race is moved by the shift device to position the clutch actuator through the inner race to the neutral position where power is not transmitted to the second shaft and in the operating position where the first clutch mechanism is engaged and the second shaft rotates in the forward direction. The second bearing assembly is substantially identical with the first bearing assembly in respect to the second clutch mechanism.
Also in accordance with the invention, the shift device within the transmission includes a shift yoke that is pivotally actuated to engage the outer bearing race of the first ball bearing assembly without engaging the inner bearing race to drive the clutch actuator. The shift device is likewise pivotally actuated by another shift yoke to engage the outer bearing race of the second ball bearing assembly without engaging the inner bearing race to second clutch actuator.
In accordance with another embodiment of the invention, a power drive and brake system comprises first and second axially aligned series mounted rotary shafts, a clutch device for transmitting power between the first and second shafts, a brake mechanism for stopping the second rotary shaft, an actuator for engaging and disengaging the clutch device and brake mechanism, and a shift mechanism for moving the actuator. The shift mechanism has an engaged position where the clutch device is engaged and the brake mechanism is disengaged, a neutral position wherein both the clutch device and the brake mechanism are disengaged and a braked position where the clutch device is disengaged and the brake mechanism is engaged. In the embodiment disclosed, the power drive and brake system also includes a clutch brake carrier operatively secured to both the clutch device and the brake mechanism. A spring is preferably provided to bias the clutch brake carrier in a direction to engage the clutch device and transmit power between the first and second rotary shafts to provide for the engaged condition.
The shift mechanism of the power drive and brake system is pivoted between the engaged position, the neutral position and the braked position to indirectly move the clutch brake carrier through a cylindrical sleeve and a thrust bearing from the engaged position where the clutch mechanism is engaged and power is transmitted from the first rotary shaft to the second rotary shaft, to the neutral position where the clutch mechanism the brake mechanism are disengaged allowing rotary movement of the first rotary shaft and independent rotary movement of the second rotary shaft, to the braking position where the brake mechanism is engaged and the clutch mechanism is disengaged for rotary movement of the first rotary shaft while the second rotary shaft is braked to stop rotary movement.
The clutch device of the power drive and brake system includes first interleaved, multiple friction plates mounted about the first shaft, and the brake mechanism includes second interleaved, multiple friction plates mounted about the second shaft whereby movement of the clutch brake carrier towards the clutch mechanism compresses the first interleaved, multiple friction plates and movement of the clutch brake carrier towards the brake mechanism compresses the second interleaved, multiple friction plates. Brake adjustment components are provided for adjusting the distance between the second interleaved, multiple friction plates.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure, operation, and advantages of the presently preferred embodiment of the invention will become further apparent upon consideration of the following description taken in conjunction with the accompanying drawings, wherein:
FIG. 1 a top elevation, partially cross sectioned view of a power transmission, having forward, neutral, and reverse condition in accordance with the present invention;
FIG. 2 is a perspective, exploded view of selected transmission components of FIG. 1 relating to the clutch and shifting mechanism:
FIG. 3 illustrates a partially cross sectioned, side elevational view of a power drive system having clutched, neutral, and brake conditions in accordance with the present invention; and,
FIG. 4 is a perspective, exploded view of the clutch brake components and shifting mechanism of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is illustrated a power drive system such as a power transmission 10 including a housing 12 with power transmitting rotary or rotatable shafts 14 and 16 mounted therein. The rotary shafts 14 and 16 are typically input and output shafts, respectively, and are arranged with their rotary axis in spaced, neighboring, parallel relation with respect to one another. Shafts 14 and 16 are rotatably journalized in conventional, anti-friction bearing assemblies 18, 24, 26, and 32 (18-32). While non-inset ball bearings are illustrated, it is within the terms of the invention to substitute any type of conventional anti-friction bearing. These bearings could be eliminated if desired with the actuating bearings providing the support for the shafts 14 and 16. Bearings 20, 22, 28, and 30 are also mounted to serve an additional function of actuating an element movable in the direction of the axes 34 and 36 through power shafts 14 and 16, respectively, as discussed in detail hereinafter.
Actuation mechanisms 38 and 40, as illustrated in FIG. 2, are mounted about shafts 14 and 16, respectively, and include many identical components in their construction. The actuation mechanisms 38 and 40, in the preferred embodiment, are interleaved, multiple friction plate clutches which include a plurality of friction discs 42,44,46,48 (42-48) and 42',44',46',48' (42'-48') having circular through bores 49 and 49', respectively therethrough Throughout the specification, where elements are substantially identical, prime numbers are used to indicate like elements having identical unprimed numbers. The friction discs 42-48 and 42'-48' are drivingly but slidingly mounted on shafts 14 and 16, respectively by a spline interface. Interleaved between the friction discs 42-48 and 42'-48' are clutch plates 50,52,54 and 50',52',54' having circular through bores 56 and 56', respectively, therethrough for slidable non-driving mounting on shafts 14 and 16, respectively. Clutch plates 50,52,54 (52-54) and 50',52',54' (52'-54') have a plurality of grooves 58 and 58', generally semicircular, and spaced about the outer edge surface of the clutch plates to drivingly engage clutch pins 60 and 60' protruding outward from the face of clutch carriers 62 and 62' so as to interconnect the clutch plates to their respective gears 62, 62' as later described, respectively. Each of the clutch carriers 62 and 62' is a gear having a circular through bores 64 and 64' for a sliding non-driving mounting on shafts 14 and 16, respectively, and axial external gear teeth 66 and 66', respectively, about their outer peripheral surfaces. Means 70 and 72, to engage the clutch mechanisms 38 and 40, are an important aspect of the invention and are discussed in detail below.
A gear 74 with axial inner splines around its internal cylindrical surface is drivingly connected to splines 76 about shaft 14 for rotation therewith. In the preferred embodiment, gear 74 can also slide on the shaft 14, more for ease of assembly than anything else. Gear 74 is disposed between and in abutting relation with the inner race of bearing 22 and the end friction plate 48. The other race of the bearing 22 is out of contact with the gear 74 for reasons later set forth. This outer race of bearing 22 is supported to the outer race of the bearing 24 by large diameter washers. This allows for the rotation of the inner race of bearing 22 in respect to the outer race. An idler gear 78, as seen in FIG. 2, is rotatively mounted to the case of the transmission 10 by a fixed idler shaft drivingly engaged to both the gear 74 and the gear teeth on clutch carrier 62', as discussed in more detail hereinafter for transmitting same direction rotary movement therebetween.
A gear 80, having axial inner splines around its internal cylindrical surface, is splined, in a known manner, to splines 82 about shaft 16. Gear 80 is disposed between and in abutting relation with the inner race of bearing 28 and a washer 84, which in turn is abutted against the end friction plate 42'. Again, the outer race of bearing 28 is out of contact with the gear 80. Further, gear 80, as seen in FIG. 1, is engaged with the gear teeth on clutch carrier 62.
Means 70 and 72, to engage the mechanisms 38 and 40, include shift yokes 86 and 86' having through bores 88 and 88' which are of a larger diameter than power shafts 14 and 16 that extend therethrough to enable pivotable motion, as discussed below. Shift yokes 86 and 86' are generally cylindrical in shape and include an arm 90 and 90' which extends radially outward from the peripheral edge surface 92, 92' thereof. Further, the shift yokes 86 and 86' include generally semicircular lips 94 and 94' which extend axially outward from side surfaces 96 and 96'. These lips 94, 94' are part of the main activating force mechanism in the preferred embodiment. In this embodiment the outer race of the bearings 28, 28' are the contact surfaces for the lips 94, 94'. For this reason, the lips 94 are outer axial surfaces which extend from and are integral with the peripheral edge surfaces 92, 92' and inner axial surfaces 98 and 98' which are radially spaced from through bores 88 and 88'. With these dimensions, this lip 94, 94' overlaps the outer race of the bearing 20, 28 respectively (but not the inner race for reasons later set forth). Adaptations would have to be made for alternated bearing systems.
The shift yokes 86 and 86' are disposed in power transmission 10 with their side surfaces 100 and 100' abutted against anti-friction bearings 18 and 26, respectively, and their lips 94 and 94' abutted against the outer races of the anti-friction bearings 20 and 28. The free ends of arms 90 and 90' are disposed adjacent to each other so as to provide an actuation point for external control. In the preferred embodiment, a cylindrical shifter 102 is used to move arms 90 and 90'. The cylindrical shifter 102 is supported in the housing 12 and has a notch 104 forming a "D" shaped cam surface which selectively engages the free ends of arms 90 and 90' as later described. Note that the opposite ends 104,106 and 104',106' of lips 94 and 94', respectively, are aligned with the center lines 34 and 36.
When shifter 102, as seen in FIG. 1, is rotated in the counterclockwise direction, the end of arm 90 is raised and pivots the shift yoke 86 about the outer edge surface 108. This pivotable movement presses the outwardly facing axial surface 110 of lip 94 against the outer race 112 of bearing 20. This axially slides the clutch carrier 62 (via the inner race of bearing 20 and an intermediate washer 99) to engage clutch mechanism 38, as discussed more fully below. It is important that the inner race of bearing 20 is not engaged by the shift yoke 86 because otherwise the bearing 20 would be useless as a rotary force passing member. Also, due to the pivoting of the shift yoke 86 to contact the outer race of bearing 18 together with the bore 88 in the center of the shift yoke, there is no interference with this bearing 18 or shaft 14 at this point either.
Conversely, when shifter 102, as seen in FIG. 1, is rotated in the clockwise direction, the end of arm 90' is raised and pivots the shift yoke 86' about the outer edge surface 108'. This pivotable movement presses the outwardly facing axial surface 110' of lip 94' against the outer race 114 of bearing 28. This slides the gear 80 in the axial direction to engage clutch mechanism 40, as discussed more fully below, Here also, the inner race of bearing 28 or bearing 26 is not engaged by the shift yoke 86'. A washer 99' rotatively interconnects the gear 62 to the inner race of the bearing 30 so as to allow the free rotation of such gear 62'. (The outer race of the bearing 30 is supported to the outer race of bearing 32 by larger diameter washers.)
The power transmission 10 of FIGS. 1 and 2 has input and output rotary shafts 14 and 16, respectively, arranged in neighboring axis alignment with each other. Interleaved clutch mechanisms 38 and 40 are mounted around shafts 14 and 16, respectively, and are operated by shift yokes 86 and 86' which in turn are controlled by the cylindrical shifter 102. The arrangement is such that when either clutch mechanism 38 or 40 is engaged, the other is disengaged so that power is transmitted in either one direction or the other direction, as will be more fully explained below. Further, due to the use of a single cylindrical shifter 102 there is a neutral position where neither clutch is engaged, as seen in FIG. 1. This sequential operation is preferred, especially when the transmission is used as a forward/neutral/reverse shift device for lawn mowers. It is understood that while this arrangement transmits a bi-directional flow of power, either shaft can be used as the input shaft while the other is the output shaft.
The transmission 10 shown is utilized as the forward/neutral/reverse mechanism for a lawn mower. In this application, the transmission 10 is bolted onto a speed change main transmission. This is facilitated by the fact that the casing of the transmission 10 has the same general size, shaft location, and mounting bolt orientation as a Sundstrand 10 BDU hydrostatic transmission. This allows a manufacturer to use a single speed change main transmission with both mechanical (the invention) and hydrostatic power inputs. In operation, the transmission 10 has a power input shaft 14 connected to a source of power, such as a motor (not shown), for rotary movement. Due to the ruggedness of the disclosed embodiments of the invention, no clutch is necessary, although one could be utilized if desired. The shaft 16 is drivingly connected to main input of the speed change main transmission. When the cylindrical shifter 102 is in the neutral position, as illustrated in FIG. 1, input shaft 14 rotates gear 74 while clutch carrier 62, which is journalized on the shaft by needle bearings, does not rotate. Concurrently, idler gear 78, as illustrated in FIG. 2, which is meshed with gear 74 and directly or indirectly with the gear teeth on clutch carrier 62', rotates However, since the clutch carrier 62' is journalized on shaft 16 by needle bearings, it does not rotate the shaft 16. This is a neutral no output condition.
When the cylindrical shifter 102 is rotated in the counterclockwise direction, the outer race 112 of bearing 20 is pushed by yoke 86 in an axial direction towards clutch 38. This compresses the friction discs 42-48 to clamp the clutch plates 50-54 and effect a driving connection between shaft 14 and clutch carrier gear 62. Since carrier gear 62 is meshed with gear 80, which in turn is splined onto shaft 16, shaft 16 moves in one direction. This is a first operative driving connection with shaft 16 rotating in the opposite direction as shaft 14.
When the cylindrical shifter 102 is rotated in the clockwise direction, the outer race 114 of bearing 28 is pushed by yoke 86' in an axial direction towards clutch 40. This moves the gear 80 and the washer 84 to compress the friction discs 42'-48' to clamp the clutch plates 50'-54' and effect a driving connection between shaft 16 and clutch carrier gear 62'. Since carrier gear 62' is meshed with idler gear 78, which in turn is meshed to gear 74 splined onto shaft 16, shaft 16 moves in the other direction. This is a second operative driving condition with shaft 16 rotating in the same direction as shaft 14, at a lower speed due to the diameter of gear 74 versus gear 62. This provides for a lower speed in this direction (reverse) for the particular transmission 10 disclosed. Differing ratios or interconnections could be selected for either mechanism as desired.
One important advantage of transmission 10 is that while it is a mechanical transmission, it has the operating characteristics of a hydraulic transmission in that it can be shifted under load and has an intermediate neutral condition. Besides being sturdy and dependable, transmission 10 is relatively inexpensive to manufacture and assemble. It is also a suitable, inexpensive replacement for a conventional Sundstrand 10-BDU hydrostatic power unit as previously set forth.
In the embodiment of FIGS. 1 and 2, there are two neighboring shafts with two separate yokes 86, each establishing a single power condition.
Referring to FIGS. 3 and 4, a second embodiment of the invention relates to a power drive system 118 which incorporates the invention as a sequential clutch brake device 120 disposed between a multi-speed power unit 122, such as a Sundstrand 10-BDU hydrostatic power unit, and an output. In this instance, the output is a first stage planetary reduction unit 130, a second stage Bull reduction gear 132 and an axle 134 with a drive wheel 136 attached to the output end. Since the primary invention is directed to the clutch brake device 120, the other components of the system and their operation are only described briefly herein. The central shaft is illustrated via a power drive and brake system associated with one drive wheel. A duplicate mirror image power drive and brake system associated with another drive wheel is connected to an opposite end of the central shaft but not illustrated herein.
Power from power unit 122 is delivered through a shaft 138 to gear drive unit 124 which includes meshed bevelled gears 140 and 142. Bevelled gear 142, which is secured to central shaft 126 by conventional means, such as splines, drives the central shaft 126. Central shaft 126 is supported by conventional anti-friction bearing assemblies 140 and a bearing (not shown) in the mirror image power drive. Components of the clutch brake device 120 are generally about the free splined end 144 of shaft 126, as described in more detail below.
The clutch brake device 120 includes operator means 146 having three operational positions where a clutch mechanism 148 is engaged and a brake mechanism 150 is disengaged, where both the clutch and brake mechanisms are both disengaged and where brake mechanism 150 is engaged and clutch mechanism 148 is disengaged. Operator means 146, as shown in FIG. 4, generally includes a cylindrical sleeve 152, a shift yoke 166 and a cylindrical shifter 184.
Cylindrical sleeve 152 has a slot 154 cut in end face 156 and oppositely disposed support arms 158 and 160 extending axially outward from face 156 and having U-shaped grooves 162 and 164 at the free ends thereof. The shift yoke 166 is disposed between support arms 158 and 160 and is secured to slots in the cylindrical sleeve 152 by radially extending bolts 180, 182. These bolts 18, 182 serve the dual purpose of passing actuation forces between the yoke 166 and sleeve 152 as well as physically supporting the sleeve 152 as later described. The shift yoke 166 has a through bores 168 which is of a larger diameter than shaft 144 extending therethrough to enable pivotable motion when assembled, as discussed below.
Shift yoke 166 is generally cylindrical in shape and includes an arm 170 extending radially outward from the peripheral edge surface 172. Further, the shift yoke 166 includes a boss 174 disposed on the surface of the yoke on the opposite side of through bore 168 from arm 170. This boss 174 provides a pivoting bearing surface which also physically locates the shift yoke 166 in position as later described. Also, opposing threaded bores 176 and 178 extending radially through the sidewalls of the yoke to the through bores 168. Bolts 180 and 182 are threaded into bores 176 and 178, respectively, so that the yoke can be connected to sleeve 152 with the bolts in U-shaped grooves 162 and 164. The arm 170 is disposed within the groove 154 in an unactuated condition.
A cylindrical shifter 184 is rotatably supported in the housing 186 of the power drive and brake mechanism 118 and has a notch 188 forming a "D" shaped cam surface. This notch 188 engages the arm 170 of shift yoke 166 to pivot the shift yoke about boss 174, as discussed hereinafter. The assembled sleeve 152 and shift yoke 166 are installed in the housing so that boss 174 is received within an indentation 188 formed in an interior wall 190 of housing 186 so as to form a pivoting bearing surface. This spreads out the load between the shift yoke 166 and housing 186 more than a flat surface (set forth in the first embodiment) would do. The boss 174 also serves to retain the shift yoke 166 in its operative position in respect to the housing of the device 120 (together with bearing 142). Note that sleeve 152 abuts against interior wall 192 of housing 186 in its default, unactuated condition. This provides for a definite default positioning for the mechanism.
Clutch mechanism 148 is mounted about central shaft 126 can be a multiple friction plate clutch which includes a plurality of friction discs 194, 196, 198, 200, 202 (194-202) having circular through bores 204 therethrough. Friction discs 194-202 are slidingly mounted on the end 144 of shaft 126 connected thereto for rotation therewith by splines. Interleaved between the friction discs 194-202 are clutch plates 206, 208, 210, 212, 214 (206-214) having circular through bores 216 therethrough. Clutch plates 206-214 have a plurality of outer grooves 218 which are generally semicircular, and spaced about the outer edge surface of the plates to engage pins 220 protruding outward from opposite sides of a clutch brake carrier 222. A bearing 142 loosely positioned in the interior hole 168 of the yoke 166 acts to provide a rotating interconnection between the friction disk 194 (bearing inner race) and the housing of the device (bearing outer race). This passes the spring biasing forces to the stationary housing of the transmission while still allowing for the rotation of the shafts. The bearing 142 also insures the rough positioning of the yoke 166 about the shaft 126.
The clutch brake carrier 222 is a generally cylindrical element having a circular through bores 224 which is sized for a driving but also sliding fit on the splined end of shaft 128. One side 226 of carrier 222 has a circular groove 228 to support a radial thrust bearing assembly 230 which in turn abuts against sleeve 152. Note that in the preferred embodiment the pins 220 jut outward from the other side 232 of clutch carrier 222 and thus also form part of the operating components of brake mechanism 150, as discussed in detail hereinafter.
Outer drive shaft 128 is supported by conventional anti-friction bearing assemblies 234 and 236 and has components of the clutch brake device 120 secured to and generally about the free splined end 238 thereof. A compression spring 240, secured at one end by a ring element 242, abuts against side 232 of carrier 222 and biases the carrier against assembled clutch plates and friction discs to compress the clutch assembly against bearing 142. This spring biased clutch drivingly connects drive shaft 128 with the shaft 126, as described in more detail below. This provides a default power interconnection between shafts 126 and 128. Note that due to this default spring loaded engaged condition, no clearance adjustment mechanism is needed for the clutch mechanism 148.
Brake mechanism 150 is mounted about outer drive shaft 128 and can include a multiple friction plate brake which includes a plurality of friction discs 244 and 246 having circular through bores 248 therethrough and three equally spaced shoulders 250 having a U-shaped groove 252 for securing the discs within housing 186 by means such as bolts 253 disposed about the interior of the casing. In the preferred embodiment, the bolts 253 also hold the case together. Friction discs 244 and 246 are slidingly mounted about the pins 220 with brake plates 254 interleaved between the friction discs 244 and 246 and having circular through bores 256 therethrough. Brake plates 254 have a plurality of spaced grooves 258 which are generally semicircular, and spaced about the through bores 256 to align with and slidingly engage pins 220 protruding outward from side 232 of brake carrier 222. This locks the brake plates 254 to the carrier 222 for rotation therewith. In general, when sleeve 152 is moved axially against thrust bearing 230, the clutch brake carrier 222 presses brake friction discs 244 and 246 against brake plates 254 and thereby stops the rotation of shaft 128. This provides a braking condition for the mechanism 118. Note that this second embodiment utilizes an intermediate part, the sleeve 152, between the yoke 166 and the carrier 222. This allows the yoke 166 to be axially displaced from the bearing device for the mechanism (in contrast with the neighboring positioning in the first embodiment. The specifics of the release of the clutch and the application of the brakes will be discussed in greater detail below.
Another aspect of the invention is the provision of a brake adjustment mechanism 260, as best seen in FIG. 4. The adjustment mechanism 260 includes two adjustment discs 262 and 264 which abut against each other. Disc 262 has a flat surface 266 on one side and a plurality of spaced, ramped bosses 268 projecting axially outward on the opposite side 270. Three equally spaced shoulders 272, each having a U-shaped groove, secure discs 262 in place against rotation with means such as bolts 253 displaced about the interior of the casing. Disc 264 has a surface 274 with a plurality of spaced, ramped bosses 268' projecting axially outward therefrom. An adjustment element 276, such as a bolt within a cylinder projecting axially outward from an opposite surface 278, is secured to disc 264.
When the adjustment mechanism 260 is assembled in housing or casing 186, as illustrated in FIG. 3, the flat surface 266 of disc 262 abuts against friction disc 246 with the inner facing surfaces 270 and 274 adjacent each other so that the ramps on opposite facing ramped bosses 268 and 268' abut against each other while the flat surface 278 of disc 264 abuts against the housing 186. An adjustment bolt 290 protrudes from the exterior of the housing inward to contact the adjustment element 276. Rotation of this bolt 290 thus rotates disk 264 in respect to disk 262 so as to alter the axial spacing between the outward faces of disks 264 and 262 (thus increasing the relative thickness of the combination), This in turn adjusts the clearances in the brake mechanism 150. When the power drive system 118 is first assembled, the adjustment bolt 290 is utilized to rotate disk 264 in respect to disk 262 so that there is a neutral condition between release of the clutch mechanism 148 and application of the brake mechanism 150. The bolt 290 is then locked in place. This provides for a sequential operation with the extent of the intermediate neutral condition dependent on the value of the clearances between plates in the brake mechanism 150. When the brakes need adjustment, such as when they become worn, the adjustment bolt 290 can be again utilized in the field to cause movement of disc 264 with respect to stationary disc 262 and thus the latter disc against the brake discs and friction plates to adjust them so that a differing, normally less movement is necessary to apply the brakes.
In operation, the power drive and brake mechanism 118 has a power input shaft 138, which is powered by means such as a power unit 122, that transmits power through a gear drive unit 124 to central shaft 126. When cylindrical shifter 184 is in the default drive position, as illustrated in FIG. 3, compression spring 240 biases clutch brake carrier 222 against clutch mechanism 148 so that rotary power is transferred through the clutch mechanism 148 and clutch brake carrier to drive shaft 128. The power is then transferred through a conventional, first stage planetary reduction unit 130, typically operating at a reduction ratio of 3 to 1, to a second stage full reduction gear 132. Then the power is directed through an axle 134 to a wheel 136.
When the shifter 184 is first rotated, the arm 170 is moved axially towards sleeve 152 and causes the sleeve to move against the bearing 230 which in turn moves the clutch brake carrier 222 against the compression spring 240 whereby the clutch is disengaged so that power is not delivered from the rotating central shaft 126 to outer shaft 128. In this neutral position, the brake is preferably not yet applied so that the wheel 136 turns freely. The bearing 230 utilized is preferably a thrust bearing due to its significant diameter.
When the shifter 184 is rotated further, arm 170 is moved further causing sleeve 152 to move clutch brake carrier 122 to compresses the brake mechanism 150 and stop the outer axle 128 from rotating. This in turn stops wheel 136 from rotating, thus providing a brake condition.
Note that due to the use of two clutch brake devices 120, one for either wheel drive, with no intermediate differential, the clutch brake devices 120 can be utilized together, to brake the lawn mower, or individually, to turn the lawn mower towards the activated side. It is apparent that there has been provided in accordance with this invention an improved actuator for power transmissions and planetary drive systems that satisfies the objects, means and advantages set forth herein before. That is, the transmission and planetary gear drive systems can be quickly and easily shifted between operating conditions, such as between drive, neutral and reverse conditions or between a drive, a neutral or a braked condition. Further, the transmission and planetary gear drive systems are relatively inexpensive and easy to manufacture and assemble while being sturdy to handle rough treatment by inexperienced equipment operators.
While the invention has been described in combination with embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad of the appended claims. | A pivotable actuator for changing the condition of a mechanical power transmission system between neutral, engaged and disengaged states. The transmission system comprises rotary shafts each having a clutch mechanism and a clutch actuator for engaging and disengaging the clutch mechanism. A bearing device disposed about the shafts is moved by a shift mechanism to drive the clutch actuator between the different states. In an alternative embodiment relating to an aligned shaft drive system, the clutch actuator shifts a gear drive system from an engaged condition to a neutral condition and then to a braked condition. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of co-pending and commonly-owned U.S. patent application Ser. No. 12/686,433, entitled “BIOPSY DEVICE WITH ROTATABLE TISSUE SAMPLE HOLDER,” filed Jan. 13, 2010, which is a continuation of U.S. Pat. No. 7,854,707, entitled “TISSUE SAMPLE REVOLVER DRUM BIOPSY DEVICE,” issued Dec. 21, 2010, the disclosures of which are hereby incorporated by reference in their entirety.
[0002] U.S. Pat. No. 7,854,707 is a continuation-in-part of commonly-owned U.S. Pat. No. 7,867,173, entitled “BIOPSY DEVICE WITH REPLACEABLE PROBE AND INCORPORATING VIBRATION INSERTION ASSIST AND STATIC VACUUM SOURCE SAMPLE STACKING RETRIEVAL,” issued Jan. 11, 2011, the disclosure of which is hereby incorporated by reference in its entirety.
[0003] U.S. Pat. No. 7,854,707 also claims priority to U.S. Pat. Appln. Ser. No. 60/874,792, entitled “BIOPSY SAMPLE STORAGE” to Hibner et al., filed Dec. 13, 2006, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0004] The present invention relates in general to biopsy devices, and more particularly to biopsy devices having a cutter for severing tissue, and even more particularly to biopsy devices for multiple sampling with a probe remaining inserted.
BACKGROUND OF THE INVENTION
[0005] When a suspicious tissue mass is discovered in a patient's breast through examination, ultrasound, MRI, X-ray imaging or the like, it is often necessary to perform a biopsy procedure to remove one or more samples of that tissue in order to determine whether the mass contains cancerous cells. A biopsy may be performed using an open or percutaneous method.
[0006] An open biopsy is performed by making a large incision in the breast and removing either the entire mass, called an excisional biopsy, or a substantial portion of it, known as an incisional biopsy. An open biopsy is a surgical procedure that is usually done as an outpatient procedure in a hospital or a surgical center, involving both high cost and a high level of trauma to the patient. Open biopsy carries a relatively higher risk of infection and bleeding than does percutaneous biopsy, and the disfigurement that sometimes results from an open biopsy may make it difficult to read future mammograms. Further, the aesthetic considerations of the patient make open biopsy even less appealing due to the risk of disfigurement. Given that a high percentage of biopsies show that the suspicious tissue mass is not cancerous, the downsides of the open biopsy procedure render this method inappropriate in many cases.
[0007] Percutaneous biopsy, to the contrary, is much less invasive than open biopsy. Percutaneous biopsy may be performed using fine needle aspiration (FNA) or core needle biopsy. In FNA, a very thin needle is used to withdraw fluid and cells from the suspicious tissue mass. This method has an advantage in that it is very low-pain, so low-pain that local anesthetic is not always used because the application of it may be more painful than the FNA itself. However, a shortcoming of FNA is that only a small number of cells are obtained through the procedure, rendering it relatively less useful in analyzing the suspicious tissue and making an assessment of the progression of the cancer less simple if the sample is found to be malignant.
[0008] During a core needle biopsy, a small tissue sample is removed allowing for a pathological assessment of the tissue, including an assessment of the progression of any cancerous cells that are found. The following patent documents disclose various core biopsy devices and are incorporated herein by reference in their entirety: U.S. Pat. No. 6,273,862 issued Aug. 14, 2001; U.S. Pat. No. 6,231,522 issued May 15, 2001; U.S. Pat. No. 6,228,055 issued May 8, 2001; U.S. Pat. No. 6,120,462 issued Sep. 19, 2000; U.S. Pat. No. 6,086,544 issued Jul. 11, 2000; U.S. Pat. No. 6,077,230 issued Jun. 20, 2000; U.S. Pat. No. 6,017,316 issued Jan. 25, 2000; U.S. Pat. No. 6,007,497 issued Dec. 28, 1999; U.S. Pat. No. 5,980,469 issued Nov. 9, 1999; U.S. Pat. No. 5,964,716 issued Oct. 12, 1999; U.S. Pat. No. 5,928,164 issued Jul. 27, 1999; U.S. Pat. No. 5,775,333 issued Jul. 7, 1998; U.S. Pat. No. 5,769,086 issued Jun. 23, 1998; U.S. Pat. No. 5,649,547 issued Jul. 22, 1997; U.S. Pat. No. 5,526,822 issued Jun. 18, 1996; and US Patent Application 2003/0199753 published Oct. 23, 2003 to Hibner et al.
[0009] At present, a biopsy instrument marketed under the trade name MAMMOTOME is commercially available from DEVICOR MEDICAL PRODUCTS, INC. for use in obtaining breast biopsy samples. This device generally retrieves multiple core biopsy samples from one insertion into breast tissue with vacuum assistance. In particular, a cutter tube is extended into a probe to cut tissue prolapsed into a side aperture under vacuum assistance and then the cutter tube is fully retracted between cuts to extract the sample.
[0010] With a long probe, the rate of sample taking is limited not only by the time required to rotate or reposition the probe but also by the time needed to translate the cutter. As an alternative to this “long stroke” biopsy device, a “short stroke” biopsy device is described in the following commonly assigned patents and patent applications: U.S. Pat. No. 7,419,472, entitled “Biopsy Instrument with Internal Specimen Collection Mechanism,” issued Sep. 2, 2008 in the name of Hibner et al.; and U.S. Pat. No. 7,740,597, entitled “Biopsy Device with Sample Tube,” issued Jun. 22, 2010 in the name of Cicenas et al. The cutter is cycled across the side aperture, reducing the sample time. Several alternative specimen collection mechanisms are described that draw samples through the cutter tube, all of which allow for taking multiple samples without removing the probe from the breast.
[0011] In particular, in the cross referenced U.S. Pat. Pub. No. 2006/0074345, entitled “BIOPSY APPARATUS AND METHOD”, these tissue samples are drawn by vacuum proximally through the cutter tube into a serial tissue stacking assembly that preserves the order of sample taking, can be visually observed through a transparent lumen, and can serve as a transport container for samples taken during a pathology examination.
[0012] While these known tissue storage approaches have a number of advantages, it is believed that further improvements may be made in tissue storage and transport for core biopsy procedures.
SUMMARY OF THE INVENTION
[0013] The present invention addresses these and other problems of the prior art by providing a biopsy device that has a probe cannula that is inserted into tissue to obtain a core biopsy sample by translating a cutter with the probe cannula. A pneumatic pressure differential is used to draw a severed tissue sample proximally from the probe cannula into an individual sample container. Thereafter, another empty sample container is moved into position to accept the next tissue sample.
[0014] These and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the description thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed the same will be better understood by reference to the following description, taken in conjunction with the accompanying drawings in which:
[0016] FIG. 1 is an isometric view of a biopsy device with an attached sample revolver drum assembly consistent with the present invention.
[0017] FIG. 2 is an isometric view of the biopsy device of FIG. 1 with a disposable probe assembly that includes the sample revolver drum assembly disengaged from a reusable handpiece that has a lower tray removed to expose a carriage frame assembly and a motor drive assembly.
[0018] FIG. 3 is an isometric view of the reusable handpiece of FIG. 1 with a top cover detached with a left half cut away and with the lower handle tray detached to expose the motor drive assembly operatively engaged to the carriage frame assembly.
[0019] FIG. 4 is an isometric view of the motor drive assembly removed from the carriage frame assembly of FIG. 3 .
[0020] FIG. 5 is a bottom isometric view of the top cover of the reusable handpiece of FIG. 2 .
[0021] FIG. 6 is a top, left and aft isometric view of the carriage frame assembly of FIG. 4 .
[0022] FIG. 7 is a top, left and forward view of the carriage frame assembly of FIG. 4 with an upper frame disassembled.
[0023] FIG. 8 is a top, left and front isometric view of the carriage frame assembly of FIG. 4 with the upper frame removed.
[0024] FIG. 9 is a bottom isometric view of the carriage frame assembly of FIG. 8 with the upper frame removed.
[0025] FIG. 10 is a top, left and front isometric exploded view of the carriage frame assembly of FIG. 4 .
[0026] FIG. 11 is a right front view of a transmission section of the motor drive assembly of FIG. 4 with a distal bulkhead removed.
[0027] FIG. 12 is a front left exploded view of the transmission section of the motor drive assembly of FIG. 4 .
[0028] FIG. 13 is a left front isometric view of the disposable probe assembly of FIG. 1 with a hand-held distal portion partially disassembled from the sample revolver drum assembly.
[0029] FIG. 14 is an isometric view from below and to the left of the hand-held distal portion of the disposable probe assembly of FIG. 13 with cover components omitted.
[0030] FIG. 15 is an isometric view of an exploded portion of the disposable probe assembly.
[0031] FIG. 16 is an isometric view of the sample revolver drum assembly of FIG. 1 .
[0032] FIG. 17 is an exploded view of the sample revolver drum assembly of FIG. 16 .
[0033] FIG. 18 is an isometric detail view of an indexer gear cover of the sample revolver drum assembly of FIG. 16 .
[0034] FIG. 19A is a left side diagrammatic view of a left cyclic arm shown in phantom down for engagement during a proximal stroke engaged to the indexer gear cover of FIG. 18 .
[0035] FIG. 19B is a left side diagrammatic view of the left cyclic arm shown in phantom at a proximal most position on the indexer gear cover of FIG. 18 .
[0036] FIG. 19C is a left side diagrammatic view of the left cyclic arm shown in phantom during a return distal stroke rotated upward for disengagement.
[0037] FIG. 20 is an isometric view of a revolver cylindrical drum assembly of the sample revolver drum assembly of FIG. 16 .
[0038] FIG. 21 is an isometric view of the revolver cylindrical drum of the revolver cylindrical drum assembly of FIG. 20 .
[0039] FIG. 22 is an isometric view of a revolver drum belt with a couple of removed sample vials of the revolver cylindrical drum assembly of FIG. 20 .
[0040] FIG. 23 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with both carriages advanced for closing a side aperture in a probe cannula for insertion into tissue.
[0041] FIG. 24 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with an aft carriage retracted to vent the probe cannula to the atmosphere to begin a new sample taking cycle.
[0042] FIG. 25 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with a front carriage beginning to retract, opening the side aperture and beginning to switch to supplying vacuum to the probe cannula.
[0043] FIG. 26 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with both carriages retracted supplying vacuum pressure to the side aperture to prolapse tissue into the probe cannula.
[0044] FIG. 27 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with the front carriage being distally advanced to sever tissue.
[0045] FIG. 28 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with the front carriage fully distally translated to complete severing of a tissue sample with atmosphere pressure supplied to the side aperture through a lateral lumen.
[0046] FIG. 29 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with the aft carriage distally advanced to retract the tissue sample with vacuum pressure.
DETAILED DESCRIPTION OF THE INVENTION
[0047] Turning to the Drawings, wherein like numerals denote like components throughout the several views, in FIGS. 1-2 , a biopsy device 10 includes a reusable handpiece 12 , and a disposable probe assembly 14 . A lower handle tray 16 is disassembled from upper portions of the reusable handpiece 12 to expose portions that operably engage the disposable probe assembly 14 . A sample revolver drum assembly 18 is prepared to receive the next tissue sample by an indexing assembly 19 attached to a hand-held distal portion 21 of the disposable probe assembly 14 that mounts to and is actuated by the reusable handpiece 12 . Tissue that is drawn by vacuum assistance into a side aperture 20 of a probe cannula 22 of the disposable probe assembly 14 is severed by a DC motor 24 ( FIG. 3 ) in the reusable handpiece 12 that also powers rotation and staging of the sample revolver drum assembly 18 to segregate and store the tissue samples in the order received.
[0048] With particular reference to FIG. 1 , insertion of the probe cannula 22 into tissue is integrally supported by a piercing tip 26 attached at a distal end as well as a longitudinal jack hammer motion to the probe cannula 22 selected by positioning a slide button 28 distally and depressing a forward motor button 30 . In response, the DC motor 24 drives a transmission section 31 ( FIG. 2 ) grounded to a top cover 34 of the reusable handpiece 12 to longitudinally reciprocate an internal carriage frame assembly 32 ( FIG. 2 ) that is engaged for movement with the probe cannula 22 ( FIG. 3 ). With the slide button 28 proximally positioned, depression of the forward motor button 30 causes the DC motor 24 to advance and rotate a cutter tube 36 , depicted in FIG. 1 as having been fully distally translated, closing the side aperture 20 . Depression of a reverse motor button 38 causes the cutter tube 36 to retract. Depression of a mode button 40 may cause other functions to be performed. An external conduit 42 extends from the disposable probe assembly 14 and is terminated by a filter/tube fitting 43 . Vacuum assistance passes through a lateral lumen 44 of the probe cannula 22 and distally communicates via internal vent holes 47 ( FIG. 23 ) and then enters a cutter lumen 46 that encompasses the cutter tube 36 and includes the side aperture 20 . An additional feature contemplated but not depicted includes using the mode button 40 to selectively communicate a saline supply to lateral lumen 44 to flush the probe cannula. It should be appreciated that the biopsy device 10 includes a minimum of “tethers” that would impede use, pose a tripping hazard, or extend set-up time.
[0049] Alternatively, instead of “hard-walled” lateral lumen 44 separated from the cutter lumen 46 along its length, applications consistent with the present invention may have a cylindrical probe cannula wherein the cutter tube 36 is positioned off-center to translate across a side aperture. A “soft-walled” lateral lumen may then be defined as a space between an outer diameter of the cutter tube and an inner diameter of the cylindrical probe cannula.
[0050] In FIG. 2 , the disposable probe assembly 14 has a bottom cover 48 with a distal probe mount cover 50 that assists in supporting the probe cannula 22 while allowing the longitudinal jack hammer motion. A plurality of locking tabs 52 with locking edges 54 extend upwardly through pass-through slots 56 formed in the periphery of the lower handle tray 16 to resiliently extend outwardly into engaging contact with the slots 56 . Relieved areas 58 are formed behind each locking tab 52 in a top extension member 59 that surrounds a probe support body 60 . The combination covers a cavity defined by the bottom cover 48 , which allows depression of the locking tabs 52 to unlock the disposable probe assembly 14 to install another identical or similar assembly.
[0051] A proximal end of the cutter tube 36 receives a cutter gear 62 having distal and proximal reduced diameter bearing surfaces 64 , 66 on each longitudinal side of a rotation spur gear section 68 , which engage the reusable handpiece 12 for rotation and for longitudinal translation through a distally open longitudinal aperture 70 formed in the lower handle tray 16 .
[0052] REUSABLE HANDPIECE. In FIGS. 3-13 , the reusable handpiece 12 is depicted in various states of disassembly to illustrate its operation. The transmission section 31 is part of a rigidly mounted motor drive assembly 76 that includes the motor 24 in between a planetary gearbox 78 and an encoder 80 . The battery or other power source and control circuitry are omitted in the depictions. The motor drive assembly also includes a right guide pin 82 and a left guide pin 84 . The motor drive assembly 76 is shown operably engaged to the longitudinally reciprocating carriage frame assembly 32 in FIG. 3 and is disassembled from the longitudinally reciprocating carriage frame assembly in FIG. 4 . In FIG. 4 , the right guide pin 82 is inserted proximally through a right front pin guide 86 and then through a right rear pin guide 88 , both part of an upper frame 90 of the carriage frame assembly 32 . A proximal end of the right guide pin 82 resides within a distally projecting right pin receptacle 92 ( FIG. 12 ) formed as part of a distal bulkhead 94 of the transmission section 31 . A distal end of the right guide pin 82 is received by a right pin recess 96 ( FIG. 5 ) formed in the top cover 34 . Similarly, the left guide pin 84 is inserted proximally through a left front pin guide 98 and then through a left rear pin guide 100 , both part of the upper frame 90 of the carriage frame assembly 32 . A proximal end of the left guide pin 84 resides within a distally projecting left pin receptacle 102 , respectively formed as part of the distal bulkhead 94 of the transmission section 31 . A distal end of the left guide pin 84 is received by a left pin recess 104 ( FIG. 5 ) formed in the top cover 34 .
[0053] With particular reference to FIGS. 3, 4, 6, 7 and 12 , a right front ring bearing 106 is inserted over a distal portion of the right guide pin 82 and is received within a cylindrical recess 108 formed on a distal side of the right front pin guide 86 . A right aft ring bearing 109 is inserted over a proximal portion of the right guide pin 82 and is received within a cylindrical recess 111 ( FIG. 6 ) formed on a proximal side of the right aft pin guide 88 . A left front ring bearing 110 is inserted over a distal portion of the left guide pin 84 and is received within a cylindrical recess 112 formed on a distal side of the left front pin guide 98 . A left aft ring bearing 113 ( FIG. 9 ) is inserted over a proximal portion of the left guide pin 84 and is received within a left cylindrical recess 115 ( FIG. 6 ) formed on a proximal side of the left rear pin guide 100 A right compression spring 114 is proximally received over the right guide pin 82 between the right front and rear pin guides 86 , 88 . More particularly, the right compression spring 114 is distally positioned against the right front pin guide 86 and at its proximal end by a right downwardly projecting structure 116 ( FIG. 5 ) formed on an interior of the top cover 34 that closely encompasses a top portion of the right guide pin 82 without contacting other portions of the carriage frame assembly 32 . A left compression spring 118 is proximally received over the left guide pin 84 between the left front and rear pin guides 98 , 100 . More particularly, the left compression spring 118 is distally positioned against the left front pin guide 98 at its distal end by a left downwardly projecting structure 120 ( FIG. 5 ) formed on the interior of the top cover 34 that closely encompasses a top portion of the left guide pin 84 without contacting other portions of the carriage frame assembly 32 . Thereby, the carriage frame assembly 32 is biased to a distal position relative to the top cover 34 and lower handle tray 16 .
[0054] In FIGS. 3-5 , a forward projecting cylindrical resilient member 122 fastened to the upper frame 90 reduces noise by contacting the front interior of the top cover 34 slowing distal movement of the carriage frame assembly 32 prior to reaching full travel. The distal bulkhead 94 is restrained by being proximal to a top ridge 123 , a right ridge 125 , and a left ridge 127 ( FIG. 5 ) formed in the interior of the top cover 34 and to a bottom ridge 129 formed on an upper surface of the lower handle tray 16 .
[0055] Returning to FIGS. 3-4 and 7 , the upper frame 90 has right and left front shaft apertures 124 , 126 that respectfully receive for rotation a distal end of a rotation shaft 128 and a translation shaft 130 . The right front shaft aperture 124 is closed by the front portion of a right lower frame 131 of the carriage frame assembly 32 . The left front shaft aperture 126 is closed by the front portion of a left lower frame 132 of the carriage frame assembly 32 . A front (cutter) carriage 134 and an aft (straw) carriage 136 are received on the translation shaft 130 and are encompassed by the upper and lower frames 90 , 132 . In FIG. 6 , a proximal beveled and slotted end 138 of the rotation shaft 128 extends out of right aft shaft aperture 140 formed in the upper frame 90 for engagement to the transmission section 31 and is closed by an aft portion of the right lower frame 131 . A proximal slotted end 142 of the translation shaft 130 extends out of a left aft aperture 144 formed in the upper frame 90 for engagement to the transmission section 31 and is closed by the lower frame 132 . A threaded receptacle 146 on the aft end of the upper frame 90 receives a proximally projecting bolt 148 having an upwardly directed strike pin 148 at its proximal end.
[0056] In FIGS. 7-10 , the carriage frame assembly 32 sequences translation of the front and aft carriages 134 , 136 . With particular reference to FIG. 10 , the front and aft carriages 134 , 136 respectively include lower longitudinal grooves 152 , 154 that slide upon a lower rail 156 upwardly presented on the left lower frame 132 . The front and aft carriages 134 , 136 respectively include an upper longitudinal groove 158 , 160 that slides upon a rail (not shown) downwardly presented on the upper frame 90 . The translation shaft 130 has a distal overrun portion 162 and a center overrun portion 164 separated by a front threaded portion 166 that a threaded bore 168 of a front main body portion 169 of the front carriage 134 traverses in response to rotation of the translation shaft 130 . A front translation compression spring 170 on the translation shaft 130 distal to the front carriage 134 compresses to allow the front carriage 134 to free wheel when being distally advanced and then biases the front carriage 134 aft to engage the front threaded portion 166 for being retracted upon reversal of rotation of the translation shaft 130 .
[0057] With particular reference to FIGS. 8 and 10 , proximal to the center overrun portion 164 is an aft threaded portion 172 and then a proximal overrun portion 174 that a threaded bore 176 of a back main body portion 177 of the aft carriage 136 traverses in response to rotation of the translation shaft 130 as well as in response to a connection to the front carriage 134 . In particular, a front bracket 178 mounted on a right side of the front carriage 134 has a rightward front pin guide 180 that receives a distal end of a longitudinally aligned carriage limiting rod 182 . A distal threaded end 184 of the carriage limiting rod 182 extends distally out of the rightward front pin guide 180 and is prevented from backing out by a front nut 186 . A long compression spring 188 is received over a shaft 190 of the carriage limiting rod 182 proximal to the rightward front pin guide 180 . An aft bracket 192 is attached to a right side of the back main body portion 177 of the aft carriage 136 to extend a rightward aft pin guide 194 that receives the carriage limiting rod 182 , which extends a proximal threaded end 196 proximally out of the rightward aft pin guide 194 to receive an aft nut 198 that limits forward movement. The long compression spring 188 biases the aft carriage 136 away from the front carriage 134 , delaying retraction of a tissue sample until cutting is complete when full distal translation of the front carriage 134 pulls the aft carriage 136 onto the aft threaded portion 172 .
[0058] With particular reference to FIG. 9 , a lengthwise engagement aperture 200 , defined between the right and left lower frames 131 , 132 , presents engaging structures that actuate the disposable probe assembly 14 and the revolver drum assembly 18 . The rotation (spur) gear 128 exposes its left side to the lengthwise engagement aperture 200 for engagement with the rotation spur gear section 68 of the cutter gear 62 to impart a rotation. The front bracket 178 has a downward distal half cylinder recess 202 sized to grip the distal reduced diameter bearing surface 64 of the cutter gear 62 ( FIG. 2 ). The front bracket 178 further has a downward proximal half cylinder recess 204 proximally spaced and sized to grip the proximal reduced diameter bearing surface 66 of the cutter gear 62 ( FIG. 2 ) as well as a downwardly projecting front actuation finger 206 to the left side and below of the cutter gear 62 for effecting atmospheric pressure to the probe cannula 22 . Similarly, the aft bracket 192 has a downward distal half cylinder recess 208 and a downward proximal half cylinder recess 210 proximally spaced and sized to nonobstructively translate overtop of a tissue retraction tube 211 , as well as a downwardly projecting aft actuation finger 212 that selects vacuum pressure for communicating to the probe cannula 22 .
[0059] In FIGS. 2-3 and 11-12 , the motor drive assembly 76 rotates rotation and translation shafts 128 , 130 at a fixed ratio to optimize cutting performance of the cutter tube 36 when the slide button 28 is back. Alternatively, the motor drive assembly 76 imparts a jackhammer vibration to the carriage frame assembly 32 when the slide button 28 is forward. With particular reference to FIGS. 11-12 , the planetary gearbox 78 extends proximally a keyed motor drive shaft 214 ( FIG. 12 ) through a drive shaft hole 216 formed in the distal bulkhead 94 . A slide spur gear 218 is received upon the keyed motor drive shaft 214 remaining engaged for rotation between a first distal (jack hammer) position and a second proximal (translation) position in accordance with a position of the slide button 28 whose distal and proximal feet 220 , 222 straddle the slide spur gear 218 . In FIG. 11 , the slide spur gear 218 is close to a proximal bulkhead 224 of the transmission section 31 , engaging a small spur 226 of a multiplier gear assembly 228 . The multiplier gear assembly 228 includes a longitudinal shaft 230 centrally attached to the small spur gear 226 . Proximal thereto, a cylindrical hub 232 is pinned to the longitudinal shaft 230 and in turn is encompassed by and pinned to a large spur gear 234 that rotates within a correspondingly sized, distally open recess 236 formed in proximally projecting container 237 integral to the proximal bulkhead 224 . A front cylinder bearing 238 received on a distal portion of the longitudinal shaft 230 is received by the proximal surface of the distal bulkhead 94 .
[0060] A first output drive shaft 240 distally presents a right angle prismatic end 242 shaped to engage the beveled and slotted end 138 of the rotation shaft 128 that passes through a lower right hole 244 in the distal bulkhead 94 . A cylindrical spacer 246 is received over a distal cylindrical portion 248 of the first output shaft 240 , taking up the space between the rotation shaft 128 and the proximal bulkhead 224 . A distally open recess 250 , formed as part of the container 237 that communicates from below with the recess 236 , is shaped to receive a proximal cylindrical end 252 of the first output drive shaft 240 and encompasses cylindrical bearing 254 as well as a small spur gear segment 256 , which is distal thereto and engages the large spur gear 234 of the multiplier gear assembly 228 .
[0061] A second output drive shaft 258 distally presents a right angle prismatic end 260 to engage the proximal slotted end 142 of the translation shaft 130 that extends through a low left hole 262 in the distal bulkhead 94 . A cylindrical spacer 264 is received over a distal cylindrical portion 266 of the second output drive shaft 258 proximal to the right angle prismatic end 260 and distal to a wider diameter hub segment 268 that is encompassed by and pinned to a large spur gear 270 that engages the small spur gear 226 of the multiplier gear assembly 228 . Proximal to the hub segment 268 is a wide spacer segment 272 and then a narrow cylindrical end 274 that receives a cylindrical bearing 276 that resides within a correspondingly-sized, distally open recess 278 that communicates from the left with the recess 236 and is formed as part of the same container 237 .
[0062] The distal and proximal bulkheads 94 , 224 are structurally attached to one another in parallel alignment traverse to the longitudinal axis of the biopsy device 10 by cylindrical legs 280 molded to and proximally projecting from rectangular corners of the distal bulkhead 94 and fastened to the proximal bulkhead 224 . In addition, a pin 282 passes through holes 281 , 283 longitudinally aligned in the distal and proximal bulkheads 94 , 224 respectively along a top surface.
[0063] When the slide button 28 is moved distally to the jackhammer position, the sliding spur gear 218 disengages from the small spur gear 226 and engages a large spur gear 284 of a rotary camming gear assembly 286 . A camming shaft 286 from distal to proximal includes a distal cylindrical end 288 , a cam wheel 290 , a mid-shaft portion 292 that receives the upwardly directed strike pin 150 of the proximally projecting bolt 148 , a wide diameter hub 294 that is encompassed by and pinned to the large spur gear 284 , and a proximal cylindrical end 296 . A distal cylindrical bearing 298 is received within a proximally open container 300 projecting distally from the distal bulkhead 94 and in turn receives the distal cylindrical end 288 of the camming shaft 286 . A proximal cylindrical bearing 302 is received within a distally projecting and open cylinder 304 formed on the proximal bulkhead 224 and in turn receives the proximal cylindrical end 296 of the camming shaft 286 .
[0064] As the camming shaft 286 rotates clockwise as viewed from behind, the cam wheel 290 presents a proximal surface to the distal edge of the strike pin 150 that is more proximal until the interrupted portion of the camming wheel 290 is presented, allowing the strike pin 150 to return to a distal position under the urging of the distal biasing of the right and left compression springs 114 , 118 .
[0065] DISPOSABLE PROBE ASSEMBLY. In FIGS. 13-29 , the disposable probe assembly 14 has movable components that respond to the actuating motions of the reusable handpiece 12 . With particular reference to FIGS. 13-15 , the distal portion 21 of the disposable probe assembly includes the probe cannula 22 that is supported by the probe support body 60 . The probe support body 60 includes a distal probe mount 306 that is received within the distal probe mount cover 50 of the bottom cover 48 . The front carriage 134 controls a vacuum valve 307 . In particular, proximal to and underlying a longitudinal axis of the disposable probe assembly 14 defined by a probe guide hole 308 passing through the distal probe mount 306 , a vertically open longitudinal trough 310 is formed into a necked portion 312 of the probe support body 60 . A cutter carriage-driven vacuum valve driver 313 has an elongate driver body 314 that longitudinally translates within the longitudinal trough 310 and upwardly presents an elongate slot 315 for being indirectly moved by the downwardly projecting front actuation finger 206 of the front carriage 136 .
[0066] With reference also to FIG. 23 , a proximal block portion 316 is attached to the necked portion 312 of the probe support body 60 . A lower mounting 317 extends from the elongate driver body 314 distal to and longitudinally aligned with a distally open, longitudinally aligned vacuum valve bore 318 ( FIG. 23 ) formed in proximal block portion 316 of the probe support body 60 . Central and proximal ports 320 , 321 communicate with the vacuum valve bore 318 from an underside of the proximal block portion 316 and a distal port 322 communicates laterally from a right side of the proximal block portion 316 . A right distal 90-degree fitting 319 communicates between the distal port 322 and an intake filter 323 within an outer hose fitting 324 .
[0067] A vacuum valve control rod 325 has a distal actuating portion 326 extending distally out of the valve bore 318 with a distal end positionable under the downwardly open portion of the longitudinal trough 310 and attached to the lower mounting 317 of the vacuum valve driver 313 . The vacuum valve control rod 325 also has a valve spool portion 327 that longitudinally translates within the valve bore 318 to selectively position between a first position and a second position. A proximal O-ring 328 near a proximal end of the valve spool portion 327 and a distal O-ring 329 are spaced such that the first position entails the O-rings 328 , 329 bracketing the central and distal ports 320 , 322 and the second position entails the O-rings 328 , 329 bracketing the proximal and central ports 321 , 320 , respectively.
[0068] The aft carriage 136 controls an air valve 351 . In particular, an air valve body 330 is attached to a left side of the proximal block portion 316 and includes a distally open longitudinal air valve bore 331 ( FIG. 23 ) depicted in FIG. 14 as accessed by a distal left port 332 , a left center port 333 , and a left proximal port 334 . An air valve control rod 335 has a distal actuating portion 336 extending distally out of the air valve bore 331 . The valve control rod 335 also has a valve spool portion 337 that longitudinally translates within the air valve bore 331 to selectively position between a first position and a second position. A proximal O-ring 338 near a proximal end of the valve spool portion 337 and a distal O-ring 339 are spaced such that the first position entails the O-rings 338 , 339 bracketing the central and distal ports 333 , 332 and the second position entails the O-rings 338 , 339 bracketing the proximal and central ports 334 , 333 , respectively.
[0069] A valve connecting vacuum conduit 340 has one end attached to a lower center ninety-degree fitting 341 attached to the central port 320 of the vacuum valve bore 318 and the other end attached to an aft left ninety-degree fitting 342 that communicates with the left proximal port 334 of the air valve bore 331 . A distal conduit 343 is attached at one end to a center ninety-degree fitting 344 that communicates with the left center port 333 and at the other end at a probe union ninety-degree fitting 345 that communicates with the lateral lumen 44 . A vacuum supply conduit 346 is attached at one end to a distal ninety-degree fitting 347 that communicates with the proximal port 321 and at the other end to a vacuum supply (not shown). An air supply conduit 348 is attached at one end to a distal ninety-degree fitting 349 that communicates with the distal left port 332 and the other end to an air supply (not shown).
[0070] The front actuation finger 206 of the front carriage 136 ( FIGS. 9-10 ) is received within an upwardly open socket 350 formed on a left side of a cutter carriage-driven indexing shuttle 352 having a lateral concave recessed band 354 shaped to encompass with a clearance a lower portion of the rotation spur gear section 68 of the cutter gear 62 . An indexing arm 355 attached to the indexing shuttle 352 includes a proximally directed portion that proximally terminates in a rightward portion that terminates in an upward portion. In FIG. 14 , a downwardly projecting vacuum actuator lug 356 ( FIG. 14 ) attached to an underside of the indexing shuttle 352 is received within the elongate slot 315 of the vacuum valve driver 314 to selectively communicate the vacuum supply to the probe cannula 22 . An air shuttle 358 longitudinally rides on a left edge of the necked portion 312 of the probe support body 60 and upwardly projects an air valve tab socket 360 positioned to receive the aft actuating finger 212 of the aft carriage 138 . A downward mounting arm 362 of the air shuttle 358 is attached to the distal actuating portion 336 of the air valve control rod 335 extending distally out of the air valve bore 331 .
[0071] A straw hook wire 364 supports a midpoint of a sample retraction tube 363 in place upon the probe support body 60 prior to engagement with the reusable handpiece 12 . A curled lower right end passes into leftwardly opening 365 along the top right surface of the proximal block portion 316 of the probe support body 60 into a small mounting block 366 extending upwardly from a right side with a downwardly inserted pin 368 passing through the curled lower right end to hold the straw hook wire 364 in place. The straw hook wire 364 has a horizontal portion attached to the curled end that passes under the sample retraction tube 363 , bending upward and then bending leftward and horizontally again through a lateral slot 370 in a vertical wire support member 372 formed onto a left side of the top surface of the proximal block portion 316 . It should be appreciated that engagement of the reusable handpiece 12 forces the left portions of the straw hook wire 364 out of engagement with the midpoint indented feature 350 as a rib feature 373 ( FIG. 9 ) deflects the left portion of the straw hook wire 364 . This facilitates commonality with disposable probe assemblies in which the straw hook wire 364 keeps a translating sample retraction straw in place prior to mounting to the reusable handpiece 12 (not shown).
[0072] With particular reference to FIGS. 16-17 , the sample revolver drum assembly 18 includes a revolver cylindrical drum 380 encompassed by a detachable revolver drum belt 382 that in turn holds removable sample vials 384 forming a revolver cylindrical drum assembly 386 ( FIG. 20 ). A drum base 388 includes a half cylinder recess 389 which holds the sample revolver drum assembly 386 for rotation about the longitudinal axis and is closed by a top drum cover 390 , which may be transparent for monitoring progress in tissue collection or opaque. An indexer support base 392 of the indexing assembly 19 has a proximal surface fastened to a distal surface of the drum base 388 and extends a mounting flange 394 distally to attach to a proximal end of the hand-held distal portion 21 of the disposable probe assembly 14 . The sample retraction tube 363 passes over the mounting flange 394 and is gripped within a longitudinal groove 396 formed along a top, left side of the indexer support base 392 and passes through a hole 398 on a top left corner of a distal face of the drum base 388 .
[0073] A slotted distal drum axle 400 of the revolver cylindrical drum 380 is received within a smaller distal portion of the half cylinder recess 389 and a proximal drum axle 401 ( FIG. 21 ) is received within a smaller proximal portion of the half cylinder recess 389 . The slotted distal drum axle 400 receives an angled proximal end 402 of a shaft 404 that passes through a shaft hole 406 in the drum base 388 . A distal portion of the shaft 404 is received within a shaft recess 408 across the top of the indexer support base 392 that communicates with a half cylindrical gear recess 410 that encompasses a lower half of a large bevel gear 412 mounted on the shaft 404 . A small half cylindrical gear recess 414 receives a transversely oriented small bevel gear 416 that engages the large bevel gear 412 . A transverse shaft 418 has a left end mounted to the small bevel gear 416 and a right end mounted to a dual spur gear assembly 420 that rotates within a rightward transverse half cylindrical recess 422 formed in the indexer support base 392 .
[0074] With particular reference to FIG. 18 , a top indexer gear cover 424 mounts overtop of the indexer support base 392 that contacts the top surfaces of the shaft 404 and left and right axle ends 426 , 428 of the dual spur gear assembly 420 with a leftward slot 430 that exposes a top portion of the large bevel gear 412 and distally open left and right vertical slots 432 , 434 that expose top surfaces of a left and right spur gear 436 , 438 of the dual spur gear assembly 420 . In FIG. 17-18 , a central beam 440 , defined between the left and right vertical slots 432 , 434 , has a T-shaped hold down spring 442 mounted on top with its narrow end 444 mounted to a proximal end of the central beam 440 . A laterally wider end 446 extends overtop of both vertical slots 432 , 434 . A cyclic spring gate 448 extends laterally to the left and right from a proximal end of the T-shaped hold down spring 442 and ramps downwardly and proximally.
[0075] With particular reference to FIG. 18 , each side of the central beam 440 has a respective left and right lower pin guides 462 , formed as an upper surface of a wider lower portion. An upper pin guide 449 extends laterally out from the central beam 440 on each side and is spaced respectively above the lower pin guides 462 , 470 to form a lower pin channel 451 . Although only the left upper pin guide 449 is depicted, it should be appreciated that the right side includes a mirror image upper pin guide. A rear ramped portion 453 of the upper pin guide 449 underlies and supports the cyclic spring gate 448 .
[0076] Left and right cyclic arms 450 , 452 have distal ends mounted on respective ends of a transverse cyclic axle 454 whose central portion passes through a top end 456 of the index arm 355 . Left fore and aft cyclic pins 458 , 460 extend rightward out of the left cyclic arm 450 . Right fore and aft cyclic pins 466 , 468 extend leftward out of the right cyclic arm 452 . Each cyclic arm 450 , 452 includes a respective left and right bottom rack segment 472 , 474 close to the distal rotating end positioned to engage a respective spur gear 436 , 438 under the downward urging of the laterally wider distal end 446 of the T-shaped hold spring 442 .
[0077] With reference to FIG. 16 , the left cyclic arm 450 is at its distal most position. It should be appreciated that the left aft cyclic pin 460 is distal to the upper pin guide 449 . In FIG. 19A , proximal movement of the right cyclic arm 450 presents the rack segment 472 to rotate the left spur gear 436 (not shown in FIG. 19A ) top aft, held in engagement by the T-shaped hold down spring 442 . Proximal movement of the cyclic arms 450 , 452 causes the dual spur gear assembly 420 and thus the small bevel gear 416 to rotate top aft, which in turn causes the large bevel gear 412 and revolver cylindrical drum assembly 386 to rotate top right, indexing the sample vial 384 to the sample retraction tube 363 in the hole 398 . In FIG. 19B , the right cyclic arm 450 has reached its proximal most position, wherein the left aft pin 460 has pushed through the cyclic spring gate 448 and out of the lower pin channel 451 . In FIG. 19C , upon distal movement of the right cyclic arm 450 , the left aft pin 460 rides up the cyclic spring gate 448 , rotating the right cyclic arm 450 out of engagement with the left spur gear 436 . It should be appreciated that the left aft pin 460 will drop off of the front of the upper pin guide 449 as the distal most position is reached and be positioned to enter again the lower pin channel 451 under the downward urging the T-shaped hold down spring 442 .
[0078] In FIGS. 20-22 , the revolver cylindrical drum 380 includes radially spaced longitudinal recesses 476 shaped to receive respective cylindrical vial holders 478 formed in the revolver drum belt 382 that hold the sample vials 384 . Each vial holder 478 includes an elongate outward aperture 480 so that contents of the retained vial 384 may be viewed. In order that pathology may ascertain which sample vial 384 received the first and subsequent tissue samples, the revolver drum belt 382 terminates in first and second belt retaining ears 482 , 484 that are drawn into longitudinal abutment and inserted into a longitudinal indexing and retention slot 486 formed in the revolver cylindrical drum 380 as the circled revolver drum belt 382 is slid longitudinally onto the revolver cylindrical drum 380 . A V-shaped slot 488 of the slotted distal drum axle 400 assures that the angled proximal end 402 of the shaft 404 is in an initial condition with a narrow aspect upward to receive the open side of the V-shaped slot 488 , which registers the retaining ears 482 , 484 to a known position prior to commencing sampling.
[0079] In FIGS. 23-29 , the operation of the reusable handpiece 12 and the hand-held distal portion 21 of the disposable probe assembly 14 are depicted sequentially in diagrammatic form to illustrate how the indexing assembly 19 and revolver drum assembly 18 are operated in conjunction with the taking of vacuum assisted core biopsy samples. In FIG. 23 , the hand-held distal portion 21 of the disposable probe assembly 14 has both carriages 134 , 136 distally advanced in an initial state for closing the side aperture 20 in the probe cannula 22 for insertion into tissue. The front carriage 134 also advances the cutter carriage-driven vacuum valve driver 313 to its distal position, switching the vacuum valve 307 distally to provide atmospheric pressure to the air valve 351 (i.e., atmosphere in distal port 322 and out center port 320 to left proximal port 334 ). The aft carriage 136 positions the air valve 351 to shut off the input from the vacuum valve 307 , instead causing the air supply conduit 348 to communicate through the left distal port 332 to the left center port 333 to the distal conduit 343 to pressurize the lateral lumen 44 .
[0080] In FIG. 24 , the aft carriage 136 has proximally retracted, switching the air valve 351 so that the atmospheric pressure provided by the vacuum valve 307 now communicates through the left proximal port 334 to the left center port 334 to the distal conduit 343 to the lateral lumen 44 , venting the probe cannula 22 to begin a new sample taking cycle.
[0081] In FIG. 25 , the front carriage 134 has begun to proximally retract while the aft carriage 136 remains at its proximal most position. The cutter tube 36 retracts exposing a portion of the side aperture 20 of the probe cannula 22 while the vacuum and air valves 307 , 351 remain in the same state with the probe cannula 22 vented to the atmosphere.
[0082] In FIG. 26 , the front carriage 134 has reached its proximal most position, fully retracting the cutter tube 36 to expose the side aperture 20 of the probe cannula 22 , which is now under vacuum pressure to prolapse tissue by having the front carriage 134 position the vacuum valve 307 to pass vacuum supply from the proximal port 321 through the center port 320 to the left central port 330 to the left distal port 332 to the lateral lumen 44 , drawing air through the internal vent holes 47 .
[0083] In FIG. 27 , the front carriage 134 has begun to distally advance, severing tissue, while the vacuum valve 307 remains switched to vacuum supply and the air valve 351 remains in the state of passing the vacuum pressure through to the lateral lumen 44 .
[0084] In FIG. 28 , the front carriage 134 has been fully distally advanced, causing the cutter tube 36 to completely sever the prolapsed tissue into a tissue sample and switching the vacuum valve 307 to vent to the atmosphere. With the aft carriage 136 still back, the air valve 351 passes the atmospheric pressure to the lateral lumen 44 to vent the probe cannula 46 .
[0085] In FIG. 29 , the aft carriage 136 has been distally advanced, switching the air valve 351 to pass air pressure from the left distal port 332 to the left center port 333 to the lateral lumen 44 . The increased air pressure passes through the holes 47 to the distal end of the cutter lumen 47 causing the tissue sample to be blown proximally back up the cutter tube 36 out of the distal hand-held portion 21 of the biopsy device 10 into the sample revolver drum assembly 18 .
[0086] The clinicians benefit from being able to visually or diagnostically image the tissue samples while still being able to maintain the probe cannula 22 in tissue to take additional samples, insert therapeutic agents, deposit a marker, etc. Thus, a minimum of reinsertions and verifications of position are necessary, yet the clinician is reassured that proper samples are being taken. Moreover, avoidance of biohazards is provided by encasing the tissue samples for convenient transport for pathology assessment. Further, the individual storage allows correlating a particular sample taken at a specific position in the patient's breast. In addition, the apparatus is portable with a minimum of needed interconnections.
[0087] It should be appreciated that any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.
[0088] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art, given the benefit of the present disclosure, that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the spirit and scope of the appended claims.
[0089] For example, while a rotating drum assembly provides an efficient means to capture a plurality of tissue samples, applications consistent with the present invention may include an uncircled belt that is drawn into a proximal portion of a biopsy device and then indexed to a next sample container with the filled sample containers on the belt moved out.
[0090] As another example, while automatically registering the next of a plurality of sample containers (e.g., vials) provides an efficient way of segregating tissue samples, applications consistent with the present invention may selectively uncouple the indexing of the next sample container. Instead, a manual selection may be made when the next sample container is to be positioned to receive the next sample. Alternatively, a separate control may be selected for the motor to drive the indexing arm or similar reciprocating element.
[0091] As another example, while a sample revolver drum assembly attached for movement with the proximal portions of the biopsy device has certain advantages, applications consistent with the present invention may include a revolver drum assembly coupled by flexible attachments, such as communicating a flexible drive capable for indexing motion.
[0092] As yet another example, while a detachable belt and detachable sample vials provide clinical flexibility, it should be appreciated that applications consistent with the present invention may include vials or similarly shaped sample containers that are immovably attached to a belt or a rigid outer cylinder wall structure.
[0093] As yet a further example, while a mechanical linkage is described herein for automatically indexing the samples, it should be appreciated that electromechanical positioning and control may be employed to sequencing sample storage. | A biopsy device comprises a probe body, a cannula extending distally from the probe body, a cutter moveable relative to the cannula to sever tissue, and a tissue sample holder coupled with the probe body. The tissue sample holder comprises a rotatable member having a plurality of recesses to receive tissue samples. The rotatable member can be operable to successively index each recess relative to a lumen defined by the cutter. A cover portion may be associated with the rotatable member and permits one or more recesses to be viewable through the cover. The recesses may be configured to carry one or more tissue samples as the rotatable member is rotated. | 0 |
RELATED APPLICATIONS
[0001] This application claims priority of U.S. provisional application Serial No. 60/347,079 filed Apr. 18, 2002.
FIELD OF THE INVENTION
[0002] This application relates generally to voice coil motors and more particularly to a coil construction for a voice coil motor.
BACKGROUND OF THE INVENTION
[0003] In a disc drive, a head for reading and writing data to and from a disc is supported on an actuator arm. The actuator arm controls the position of the head through the use of a voice coil motor (VCM), which typically includes a coil attached to an actuator assembly, as well as one or more permanent magnets which establish a magnetic field in which the coil is immersed. The controlled application of current to the coil causes magnetic interaction between the permanent magnets and the coil so that the coil moves in accordance with the well-known Lorentz relationship. As the coil moves, the actuator assembly pivots about a bearing shaft assembly, and the head (or heads) is caused to move across the surfaces of the discs.
[0004] The coil is fabricated by winding copper wire around a mandrel. Adhesion of a coil wire to the adjacent wires is accomplished by pre-coating the wire with a bond coat material and then heating the covered wire while winding the coil. The coil is heated to allow plasticizers to outgas from the coating. During this process, voids can form in the bond coat, which can result in delaminating of the bond coat from the wires. The delamination can allow individual wires in the coil to vibrate, causing undesirable noise during operation. A wire may also contact an adjacent wire if it becomes unbonded further causing undesired vibration effects. Another source of noise or unwanted vibration in current coils is out-of-plane forces. These forces cause additional vibration of the voice coil motor.
[0005] Accordingly there is a need for a coil construction that reduces the undesirable vibration due to delamination and out-of-plane forces. The present invention provides a solution to this and other problems, and offers other advantages over the prior art.
SUMMARY OF THE INVENTION
[0006] Against this backdrop the present invention has been developed. One embodiment of the present invention is directed to a coil construction for a voice coil motor. The coil construction includes a series of planar coils made from electrically conductive material formed on a substrate. The planar coils are disposed on a substrate and the coils are formed into a stacked array wherein each planar coil is separated from its neighboring coil or coils by a dampening material. The coil construction is assembled into an actuator arm for use in a disc drive and used to position a head located on the actuator arm.
[0007] Another embodiment of the invention is directed to a disc drive assembly including an actuator arm assembly for positioning a head over a disc surface. A coil construction is disposed on the actuator arm assembly and current from control circuitry through the coil construction controls the position of the head over the disc surface. The coil is a part of a voice coil motor that creates forces to move the actuator arm assembly to position the head. The coil construction includes a series of adjacent layers of stacked planar coils disposed on a substrate. The planar coils are electrically connected in series to form a single electrical current path.
[0008] These and various other features as well as advantages which characterize the present invention will be apparent from a reading of the following detailed description and a review of the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a plan view of a disc drive for incorporating an embodiment of the present invention showing the primary internal components.
[0010] [0010]FIG. 2 is a block diagram of components that control the disc drive of FIG. 1.
[0011] [0011]FIG. 3A is a perspective view from a first side of an example embodiment of a coil construction of the present invention.
[0012] [0012]FIG. 3B is a perspective view from a second side of the coil construction of FIG. 3A.
[0013] [0013]FIG. 4 is a top view of the coil construction of FIG. 3A assembled into a coil.
[0014] [0014]FIG. 5 is a perspective view of an actuator arm assembly incorporating the coil construction of FIG. 4.
DETAILED DESCRIPTION
[0015] A disc drive 100 constructed in accordance with a preferred embodiment of the present invention is shown in FIG. 1. The disc drive 100 includes a base 102 to which various components of the disc drive 100 are mounted. A top cover 104 , shown partially cut away, cooperates with the base 102 to form an internal, sealed environment for the disc drive in a conventional manner. The components include a spindle motor 106 , which rotates one or more discs 108 at a constant high speed. Information is written to and read from tracks on the discs 108 through the use of an actuator assembly 110 , which rotates during a seek operation about a bearing shaft assembly 112 positioned adjacent the discs 108 . The actuator assembly 110 includes a plurality of actuator arms 114 which extend towards the discs 108 , with one or more flexures 116 extending from each of the actuator arms 114 . Mounted at the distal end of each of the flexures 116 is a head 118 that includes an air bearing slider enabling the head 118 to fly in close proximity above the corresponding surface of the associated disc 108 .
[0016] During a seek operation, the track position of the heads 118 is controlled through the use of a voice coil motor (VCM) 124 , which typically includes a coil 126 attached to the actuator assembly 110 , as well as one or more permanent magnets 128 which establish a magnetic field in which the coil 126 is immersed. The controlled application of current to the coil 126 causes magnetic interaction between the permanent magnets 128 and the coil 126 so that the coil 126 moves in accordance with the well-known Lorentz relationship. As the coil 126 moves, the actuator assembly 110 pivots about the bearing shaft assembly 112 , and the heads 118 are caused to move across the surfaces of the discs 108 .
[0017] The spindle motor 106 is typically de-energized when the disc drive 100 is not in use for extended periods of time. The heads 118 are moved over park zones 120 near the inner diameter of the discs 108 when the drive motor is de-energized. The heads 118 are secured over the park zones 120 through the use of an actuator latch arrangement, which prevents inadvertent rotation of the actuator assembly 110 when the heads are parked.
[0018] A flex assembly 130 provides the requisite electrical connection paths for the actuator assembly 110 while allowing pivotal movement of the actuator assembly 110 during operation. The flex assembly includes a printed circuit board 132 to which head wires (not shown) are connected; the head wires being routed along the actuator arms 114 and the flexures 116 to the heads 118 . The printed circuit board 132 typically includes circuitry for controlling the write currents applied to the heads 118 during a write operation and a preamplifier for amplifying read signals generated by the heads 118 during a read operation. The flex assembly terminates at a flex bracket 134 for communication through the base deck 102 to a disc drive printed circuit board (not shown) mounted to the bottom side of the disc drive 100 .
[0019] Referring now to FIG. 2, shown therein is a functional block diagram of the disc drive 100 of FIG. 1, generally showing the main functional circuits which are resident on the disc drive printed circuit board and used to control the operation of the disc drive 100 . The disc drive 100 is operably connected to a host computer 200 in a conventional manner. Control communication paths are provided between the host computer 200 and a disc drive microprocessor 216 , the microprocessor 216 generally providing top level communication and control for the disc drive 200 in conjunction with programming for the microprocessor 216 stored in microprocessor memory (MEM) 224 . The MEM 224 can include random access memory (RAM), read only memory (ROM) and other sources of resident memory for the microprocessor 216 .
[0020] The discs 108 are rotated at a constant high speed by a spindle motor control circuit 226 , which typically electrically commutates the spindle motor 106 (FIG. 1) through the use of back electromotive force (BEMF) sensing. During a seek operation, wherein the actuator 110 moves the heads 118 between tracks, the position of the heads 118 is controlled through the application of current to the coil 126 of the voice coil motor 124 . A servo control circuit 228 provides such control. During a seek operation the microprocessor 216 receives information regarding the velocity of the head 118 , and uses that information in conjunction with a velocity profile stored in memory 224 to communicate with the servo control circuit 228 , which will apply a controlled amount of current to the coil 126 , thereby causing the actuator assembly 110 to be pivoted.
[0021] Data is transferred between the host computer 200 or other device and the disc drive 100 by way of an interface 202 , which typically includes a buffer 210 to facilitate high speed data transfer between the host computer 200 or other device and the disc drive 100 . Data to be written to the disc drive 100 is thus passed from the host computer 200 to the interface 202 and then to a read/write channel 212 , which encodes and serializes the data and provides the requisite write current signals to the heads 118 . To retrieve data that has been previously stored in the disc drive 100 , read signals are generated by the heads 118 and provided to the read/write channel 212 , which performs decoding and error detection and correction operations and outputs the retrieved data to the interface 202 for subsequent transfer to the host computer 200 or other device. Such operations of the disc drive 100 are well known in the art and are discussed, for example, in U.S. Pat. No. 5,276,662 issued Jan. 4, 1994 to Shaver et al.
[0022] To improve the acoustical performance and attenuate self-induced vibrations in an actuator arm assembly, the present invention has been developed. Referring to FIG. 5, shown is an actuator arm assembly 310 incorporating an example embodiment of a coil construction 330 of the present invention. The actuator arm assembly 310 includes a bearing housing 312 , a plurality of actuator arms 314 , and a plurality of flexures 316 , each flexure 316 supporting a head 318 , and a coil assembly 330 . While the actuator arm assembly 310 is shown supporting a plurality of heads 318 , it is not uncommon for an actuator arm assembly 310 to support only one head 318 .
[0023] The coil construction 330 is located on the actuator arm assembly 310 and is also part of the voice coil motor (VCM) (not shown) of the disc drive. Referring to FIGS. 3 A- 5 , the coil construction 330 includes a series of planar coils 336 arranged into a coil 337 that allows the actuator arm assembly 310 to move when a current is applied to the coil 337 . The coil 337 operates in the same manner as conventional coils to position the heads 318 on the actuator arm assembly 310 . The coil construction 330 is shown in FIG. 5 with the coil 337 formed and mounted to the actuator arm assembly 310 .
[0024] The coil construction 330 is formed by stacking a series of planar coils 336 each disposed on a substrate section 338 . In the example embodiment shown, the substrate sections 338 include first and second end sections 340 , 342 and a plurality of intermediate sections 344 . Each substrate section 338 is joined to its neighboring section(s) by a folding section 346 . The folding sections 346 allow the coil construction 330 as shown in FIGS. 3 A-B to be folded to form the coil 337 shown in FIG. 5, thereby forming a series of adjacent layers of planar coils 336 each bonded to a corresponding substrate section 338 . The coil construction 330 in FIGS. 3 A-B is shown in the extended position and is shown in the folded position in FIGS. 4 - 5 .
[0025] Referring to FIG. 5, the planar coils 336 are electrically connected to form a single coil 337 when the coil construction 330 is in the folded position to form the coil 337 . Each planar coil 336 is electrically connected to the adjacent planar coil 336 by through holes, or vias 360 , formed in the substrate section 338 . The electrical connection can be accomplished in various ways, which are well within the knowledge of one of skill in the art, and are not part of the present invention. Preferably, the electrical connection is made through the vias 360 by plating or a solder connection.
[0026] The coil construction 330 is mounted to the actuator arm assembly 310 by techniques known to those of skill in the art, but the coil construction 330 is preferably bonded to the actuator arm assembly 310 by an epoxy layer between the actuator arm assembly 310 and the second end section 344 of the coil construction 330 . Another preferred method of joining the coil construction 330 to the actuator arm assembly 310 is by placing the coil construction 330 in its proper position and then overmolding the entire assembly together. Overmolding typically uses a PPS (polyphenylene sulfide) or LCP (liquid crystal polymer) material that is injection molded around the entire assembly to bond all the parts together.
[0027] The coil construction 330 can also include leads 348 , 350 . The leads 348 , 350 are connected to a power source in the control circuitry and allow current to pass through the coil 337 , to move the actuator arm assembly 310 to position the heads 318 during use. The leads 348 , 350 can be omitted and the wires of the coil 337 can be directly connected to pins in the voice coil motor.
[0028] Preferably, the coil construction of the present invention is fabricated by starting with a planar sheet of substrate coated on both sides with a layer of conductive material, preferably copper. A substrate coated on a single side can be used to for the coil construction of the present invention, but using a substrate coated on both sides, such as a flex circuit with copper on both sides, lends itself to the accordion-fold embodiment described in FIGS. 3 A- 5 since it is desirable for the planar coils 336 to have the substrate material 338 between adjacent layers.
[0029] The substrate is preferably a polyimide such as KAPTON® (made by DuPont) that is suitable for use in the photolithography process, but one of skill in the art will recognize that many materials suitable for flexible circuits can be used. Preferably, the coil construction 330 is then formed using conventional photolithographic techniques. The coated substrate is covered with a photoresist and an image is patterned on the photoresist, which can be of the positive or negative type. The substrate with the photoresist is then developed and etched using techniques well known in the art. The end product is the formation of the coil construction 330 in the extended position.
[0030] Preferably, the fabrication process uses a KAPTON® substrate 0.001 inches thick that is coated on both sides with a layer of copper 0.0028 inches thick. Preferably, the copper traces that form the planar coils 336 are then processed to be approximately 0.008 inches wide, giving a trace width to material thickness aspect ratio of 2.8. One of skill in the art will recognize that the coil resistance can be controlled changing the width or height of the traces, as well as the total length of the traces through the coil. The metal layer can also be a different material on each side of the coated substrate.
[0031] After the unfolded coil construction 330 is formed, it is covered with a viscoelastic polymer adhesive and/or adhesive to achieve an optimum level of damping and structural stiffness. Preferably, epoxy or a pressure sensitive adhesive is used. The coil construction 330 is then formed into a coil 337 in the folded position by folding each of the sections 340 , 342 , 344 onto its neighboring section(s) of the coil 337 , at a fold made at each folding section 346 . The sections are folded so that there is a substrate section 338 between each planar coil 336 . If necessary, the coil construction 330 is then pressed under heated conditions to bond the successive layers together. After the folded coil construction 330 is formed it is then mounted onto the actuator arm assembly 310 and the leads 348 , 350 are electrically connected to the control circuitry (not shown) of the disc drive.
[0032] Additional features can also be integrated into the coil construction 330 of the present invention. Referring to FIGS. 4 and 5, a limit stop 352 is formed by the folding sections 346 when the coil construction 330 is in the folded position. The limit stop 352 engages with a limiting post (not shown) located in the disc drive assembly to limit travel of the actuator arm assembly 310 .
[0033] An advantage of the coil construction of the present invention is that it can be formed by creating an array of coils on a single substrate, then folding and laminating the coils in one process step, and finally cutting the laminated stack to a desired shape to create individual coils. Another advantage is that the substrate on the viscoelastic material used between the adjacent layers of planar coils acts as a damper to reduce undesirable vibrations in the coil due to the various causes discussed previously. The method of making the coil construction of the present invention also is able to create various coil shapes that are decoupled from having to develop expensive coil winding tools.
[0034] One example embodiment of the present invention is directed to a coil construction (such as 330 ) for a voice coil motor (such as 124 ). The coil construction (such as 330 ) includes a series of planar coil sections (such as 336 ) made from an electrically conductive material. The planar coil sections (such as 336 ) are electrically connected in series and each planar coil (such as 336 ) is joined to a corresponding substrate section (such as 334 ). The substrate sections (such as 334 ) include first and second end sections (such as 340 , 342 ) and at least one intermediate section (such as 344 ). Each intermediate section (such as 344 ) has two neighboring sections and each end section (such as 340 , 342 ) has one neighboring section. The coil construction (such as 330 ) forms a coil (such as 337 ) when the substrate sections (such as 334 ) are stacked.
[0035] Another example embodiment of the present invention is directed to a disc drive assembly (such as 100 ). The disc drive assembly (such as 100 ) includes an actuator arm assembly (such as 310 ) for positioning a head (such as 318 ) over a surface of a disc (such as 108 ). The disc drive assembly (such as 100 ) further includes a coil construction (such as 300 ) disposed on the actuator arm assembly (such as 310 ). The coil construction (such as 330 ) includes a series of adjacent layers of stacked planar coils (such as 336 ) disposed on a substrate. The planar coils (such as 336 ) are electrically connected in series to form a single electrical current path. The disc drive assembly (such as 100 ) also includes control circuitry electrically connected in series with the coil construction (such as 330 ) and a voice coil motor assembly (such as 124 ) for moving the actuator arm assembly (such as 310 ) to position the head (such as 318 ) when current is passed through the coil construction (such as 330 ) by the control circuitry.
[0036] It will be clear that the present invention is well adapted to attain the ends and advantages mentioned as well as those inherent therein. While a presently preferred embodiment has been described for purposes of this disclosure, various changes and modifications may be made which are well within the scope of the present invention. For example, a metallic surface can be added to the coil construction to enhance heat transfer from the coil or increase structural stiffness. Also, surfaces or sections made of polymers or composites can be added to modify the stiffness of the coil construction. Numerous other changes may be made which will readily suggest themselves to those skilled in the art and which are encompassed in the spirit of the invention disclosed and as defined in the appended claims. | A coil construction for a voice coil motor is disclosed. The coil construction includes a series of stacked planar coils disposed on a substrate material. Each planar coil is separated from its neighboring coil or coils by a viscoelastic material to reduce vibration of the coil construction. The coil construction is attached to an actuator arm. Control circuitry creates a current in the coil construction to position a head on the actuator arm. Also disclosed is a method for making a coil for a voice coil motor. The method includes the steps of masking a substrate having a conductive layer with a photoresist, exposing the mask to create a pattern of planar coils, developing the photoresist, and etching the conductive layer to create a planar coil. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to a film which comprises at least one transparent replicating layer having a diffractive relief structure and a reflective layer, a method for the production of such a film and a use of the film.
Films of the type mentioned at the outset are known and are used for securing and decorating articles, documents, packagings and the like. Metallic or nonmetallic inorganic reflective layers are used in order optimally to accentuate an optically variable effect produced by the diffractive relief structure. Such an optically variable effect manifests itself in that an observer perceives different appearances of the film at different viewing angles, such as different color impressions and/or image motifs and/or characters and/or dullness. Inter alia, holograms, holographic displays with kinematic effects and the like are recognizable.
For specific fields of use, the known films have proved to be not very suitable since the optically variable effects produced are too striking, are too strongly reflective and/or irritate the human eye. This is the case, for example, with components in the interior of a motor vehicle which are present in the direct field of view of the driver, in the case of motor vehicle number plates or the case of pieces of furniture, packagings, certain valuable documents and the like.
For these applications, films which have other security features or decorative elements are therefore relied upon.
An example of use in the area of motor vehicle number plates, which however is substantially also applicable to the other abovementioned applications, is described in more detail below by way of illustration.
Motor vehicle number plates consist as a rule of a support plate, which usually consists of an aluminum or steel sheet. A raised character legend is embossed in the support plate by means of a mechanical embossing process. The character legend usually consists of alphanumeric characters, which, for example in Germany, indicate the place of registration of the motor vehicle, and form an individual number. In order to make the character legend of the embossed motor vehicle number plate readily visible, the raised embossed areas are provided with a colored coating. A corresponding ink transfer by means of a blocking film which consists of a substrate film which is bonded to a colored decorative layer detachable therefrom is usually carried out for this purpose. During the ink transfer, the substrate film is brought into mechanical contact with the raised embossed areas of the motor vehicle number plate and the decorative layer is transferred thereto under pressure, optionally also under pressure and at elevated temperature.
In order to increase the recognizability of the character legend, the support plate is generally laminated over the whole area with a retroreflective film formed in a contrasting color to the character legend. In the case of the motor vehicle number plates usual in Germany, the front of the support plates are for this purpose laminated with a white, retroreflective film, while a black decorative film is pressed onto the character legend.
Owing to the increasing requirements with respect to the forgery protection of motor vehicle number plates, the retroreflective films laminated with the support plate of a motor vehicle number plate or the decorative films have already been provided with additional security features which are not directly recognizable with the naked human eye and therefore do not impair the appearance of the motor vehicle number plate and the readability thereof. For this purpose, the security features are formed, for example, particularly small and are introduced so that they are visible only from very specific viewing angles.
Thus, DE 102 41 803 A1 discloses a blocking film with a substrate film and a decorative layer detachable therefrom for stamping a motor vehicle number plate in the area of the character legend. The blocking film is individualized by introducing security features by removing areas of the decorative layer, changing the color of said areas or bonding said areas nondetachably to the substrate film.
Such additional security features have, however, proved to be relatively easy to copy, so that there is still a need to provide a forgery-proof film for coating the character legend. In particular, the optically variable effects which are produced by one of the films mentioned at the outset, which comprise at least one transparent replicating layer having a diffractive relief structure and a reflective layer would be of particular interest as additional security features owing to their high level of protection against forgery and/or impressive decorative effect.
This applies not only to motor vehicle number plates but also to the abovementioned components in the interior of a motor vehicle, in the case of pieces of furniture, packagings and certain valuable documents such as in the area of a magnetic stripe of a bank card and the like. There is therefore generally the need for forgery-proof and/or decorative films which, for these specific applications, substantially preserve the usual appearance of the articles coated therewith.
SUMMARY OF THE INVENTION
It is therefore the object of the invention to provide a film which has a diffractive relief structure producing an optically variable effect, the optically variable effect being recognizable or becoming recognizable to an observer only on closer examination of the film, and to provide a method for the production thereof.
The object is achieved for the film which comprises at least one transparent replicating layer having a diffractive relief structure and a reflective layer by forming the reflective layer by means of at least one pigmented lake layer which is arranged directly adjacent to the diffractive relief structure, a refractive index n 1 of the at least one lake layer and a refractive index n 2 of the replicating layer being chosen so that a contribution of a difference between imaginary parts of the refractive indices n 1 and n 2 is in the range of 0.05 to 0.7, and a lightness L* of the at least one lake layer being in the range of 0 to 90, the film showing a latent optically variable effect produced by the diffractive relief structure.
A “latent” optically variable effect is understood as meaning that the optically variable effect is recognizable for an observer of the film only under certain external conditions. In comparison with optically variable effects which are recognizable on films having metallic reflective layers, the film according to the invention shows only a weak or discrete optically variable effect which is optionally evident only under illumination by a suitable light source.
Thus, an observer recognizes not only the color effect of the at least one lake layer but furthermore an optically variable effect which is produced by the diffractive relief structure, increases the protection against forgery and/or has decorative properties, preferably only on assessment of the film according to the invention on a side of the replicating layer which faces away from the diffractive relief structure under standard illumination and at a first distance of not more than about 0.5 m from the film and/or with illumination of the film by a suitable light source or point light source, wherein recognizability may also be possible at an even greater distance with such illumination.
At the same time, however, substantially only the color effect of the lake layer is recognizable for an observer under normal illumination and at a second distance of greater than about 0.5 m from the film, in particular at a distance of at least 1 m to 2 m from the film. The optically variable effect produced by the diffractive relief structure is no longer recognizable or substantially no longer recognizable, so that the optical appearance of the article coated with a film according to the invention does not deviate or deviates only to an insignificant extent from that of a conventional, colored article.
Viewing under standard illumination is understood here as being in particular viewing of the film according to the invention in a color matching cabinet, such as, for example, byko-spectra version 2, the standard illuminant D65 being used for illumination.
The use of a pigmented lake layer instead of a metallic or nonmetallic inorganic reflective layer therefore permits the formation of a film which has latent optically variable effects which are not striking or are only slightly striking when viewed normally and do not or scarcely dazzle or irritate the eye.
The refractive index of a material is composed of a real part and an imaginary part, the imaginary part being responsible for the light absorption of the material. With the use of the at least one lake layer instead of a conventional reflective layer, the light diffraction in reflection is also partly caused by the imaginary part of the refractive index of the lake layer. The diffraction efficiencies of relief structures in the form of first order diffraction gratings are typically in the range of 0.2 to 2% here. The real part of the refractive index of a lake layer usually differs slightly from the real part of the refractive index of a replicating layer. The light diffracted by the diffractive relief structure owing to the differences in the refractive indices of the at least one lake layer and the replicating layer in reflection is furthermore superposed by the light scattered by the lake layer, with the result that the diffraction effect is weakened. The match between the light diffracted at the interface between the at least one lake layer and the replicating layer and the light scattered back by the at least one lake layer permits the formation of the latent optically variable effect. In principle, all colors can be used for coloring the at least one lake layer, but the superposition of the diffracted light with the back-scattered light is all the weaker the greater the extent to which the lake layer absorbs incident light.
A film according to the invention has the advantage that the presence of a forgery-proof or particularly attractive film is not imparted to an observer on viewing the film from a certain distance and/or on superficial viewing, but only the presence of a simple colored coating. Only on closer inspection of the film at a small distance from the film and/or under special illumination of the film or more strongly by special illumination of the film are the optically variable effects produced by the diffractive relief structure clearly recognizable, it being necessary here to assume diffraction effects which tend to be not very striking or have relatively little luminosity in comparison with the strong color effect of the pigmented lake layer.
The lightness L* of the lake layer used is determined in particular by means of the CIE-LAB Datacolor SF 600 measuring system, which is based on a spectrophotometer. In the calorimetric determination of color differences in the case of surface colors according to the CIELAB formula L*a*b*, the value L* represents the light/dark axis, the value a* represents the red/green axis and the value b* represents the yellow/blue axis. The L*a*b* color space is thus described as a three-dimensional coordinate system, the L* axis describing the lightness and possibly assuming a value between 0 and 100.
The measurement of the lightness L* is effected here under the following conditions:
Geometry of measurement: diffuse/8° according to DIN 5033 and ISO 2496 Diameter of measuring opening: 26 mm Spectral range: 360-700 nm according to DIN 6174 Standard illuminant: D65
In particular, point light sources in the form of torches, halogen lamps or motor vehicle headlights are suitable as light sources for illuminating the film according to the invention and for visualizing the optically variable effects. However, directly incident sunlight is optionally also suitable as a light source.
Preferred configurations of the film according to the invention are described below.
Here, lake layer is understood as meaning not only layers formed from colored lakes but also colored adhesive or plastic layers. The at least one lake layer is applied to the replicating layer in particular by printing, casting, applying with a doctor blade, spraying on, applying by extrusion, etc.
The layer thickness of a lake layer is in particular in the range of 1 μm to 50 μm, preferably in the range of 2 μm to 10 μm.
For the formation of a replicating layer, coating layers, in particular comprising radiation-crosslinking coatings (such as UV coatings) or thermally crosslinking coatings, are preferably used. However, thermoplastics or conventional positive or negative photoresists can also be used.
The layer thickness of a replicating layer is in particular in the range of 0.1 μm to 50 μm, preferably in the range of 0.2 μm to 1 μm. The replicating layer can, however, also serve as a self-supporting substrate film for the application of further layers, such as the at least one lake layer, and may be far thicker, for example in the range of up to 3 mm thickness.
Depending on the material chosen for the replicating layer, the relief structure is introduced into the replicating layer in particular by means of a tool appropriately profiled on its surface, such as a punch or a roll, lithographic process or laser ablation. A possible variant is provided by UV replication, in which a profiled transparent tool is brought into contact with a replicating layer comprising a UV coating and at the same time curing of the UV coating by means of a UV radiation source is effected. Thermal replication, in which a heated profiled tool is brought into contact with a replicating layer comprising thermoplastic material, is particularly preferred.
It has proved useful regarding the film if the pigmentation of the at least one lake layer is chosen so that a pigmentation number PN is in the range of 1.5 to 120 cm 3 /g, in particular in the range of 5 to 120 cm 3 /g, the pigmentation number PN being calculated according to
P N = ∑ 1 x ( m P × f ) x ( m B M + m A ) and f = ON d ,
the following being applicable:
m P =mass of a pigment in the lake layer in g, m BM =constant; mass of a binder in the lake layer in g, m A =constant; mass of solids of the additives in the lake layer in g, ON=oil absorption number of a pigment (according to DIN 53199), d=density of a pigment (according to DIN 53193), x=running variable, corresponding to the number of different pigments in the lake layer.
In this way, starting from a composition found to be suitable for a lake layer, further possible pigmentations differing therefrom can be calculated rapidly and in an uncomplicated manner.
It has proved to be advantageous if pigmentation of the at least one lake layer is chosen so that a transmittance T of visible light through the at least one lake layer is <75%.
The transmittance T, i.e. the degree of transmission of the at least one lake layer, is determined in particular by means of a spectrophotometer, for example of the Hitachi U-2000 type, measurement being effected in a wavelength range between 360 and 700 nm.
The greater the transmittance T of the pigmented lake layer, the less pronounced is the optically variable effect and the lower its degree of recognizability.
Furthermore, it has proved to be advantageous if the transmittance T of visible light through the at least one lake layer is in the range of 1 to 75%, in particular in the range of 1 to 50%, particularly preferably in the range of 1 to 25%.
It is particularly advantageous if the optically variable effect produced by the diffractive relief structure is recognizable for the observer on viewing the film on that side of the replicating layer which faces away from the diffractive relief structure, under standard illumination at a first distance of not more than about 0.5 m from the film and additionally with illumination of the film by a suitable light source. The use of a simple point light source available to everyone, for example in the form of a torch, is suitable for simple and economical monitoring of the genuineness of the film, even by an untrained person.
The optically variable effect latently produced by the diffractive relief structure manifests itself in particular in that the film, when viewed from different viewing angles, shows different colors and/or different image motifs and/or different alphanumeric characters and/or different dullnesses and the like. Optically variable elements which are present in the form of holograms, holographic displays with kinematic effect, lens elements or matt structures which are produced by means of the diffractive relief structure are particularly preferably formed. optically variable elements produced by means of linear or cross gratings have also proved useful.
A diffractive relief structure is determined in particular by parameters such as spatial frequency, azimuth, profile shape, profile height h, etc. A film according to the invention may contain two or more different types of diffractive relief structures which differ with respect to these parameters.
In general, symmetrical or asymmetrical relief structures, in particular having a sinusoidal, rectangular, sawtooth-like, etc. profile, are suitable as diffractive relief structures. The relief structure may form a diffraction grating, such as a linear grating, a cross grating, a blaze grating, a lens structure comprising concentric or nonconcentric ring structures and the like.
The spatial frequency of a diffraction grating is preferably chosen in the range of 50 to 4000 lines/mm, a range of 100 lines/mm to about 3000 lines/mm being preferred.
The geometric profile height h of a diffractive relief structure has in particular a value in the range of 50 to 5000 nm, when viewed in the cross section of the replicating layer, preferred values being in the range of 75 to 2000 nm. The profile height h is determined by determining the height difference between the highest point and the lowest point adjacent thereto of a relief structure. The highest point is so to speak defined by the peak of a mountain and the lowest point by the bottom of a valley which forms the relief structure.
The use of diffractive relief structures which have a complex surface profile with locally different profile heights is also possible. Such surface profiles may also be stochastic surface profiles which form matt structures.
On the microscopic scale, matt structures possess fine relief structure elements which determine the scattering power and can be described only by statistical characteristics, such as, for example, center line average value Ra, correlation length lc, etc., the values for the center line average value Ra being in the range of 20 nm to 5000 nm, with preferred values in the range of 50 nm to 1000 nm, while the correlation length lc in at least one direction has values in the range of 200 nm to 50 000 nm, preferably in the range of 500 nm to 10 000 nm.
The microscopically fine relief structure elements of an isotropic matt structure have no azimuthal preferred direction, and it is for this reason that the scattered light having an intensity greater than a predetermined limit, for example specified by the visual recognizability, is uniformly distributed in a solid angle predetermined by the scattering power of the matt structure, in all azimuthal directions, and the surface element appears white to grey in daylight. In the case of a change in the angle of tilt away from the vertical, the surface element appears dark. Strongly scattering matt structures distribute the scattered light in a larger solid angle than weakly scattering matt structures. If the relief elements of the matt structure have a preferred direction, such as, for example, asymmetric matt structures, the scattered light has an anisotropic distribution.
As already mentioned above, in the case of light, strongly scattering lake layers, the diffraction effects appear comparatively weak owing to the back-scattered light, whereas the diffraction effects appear strong in the case of dark, strongly absorbing colors since scarcely any light is scattered back by the lake layer. Thus, with the use of a light-pigmented lake layer, the recognizability of the latent optically variable effects is under certain circumstances so greatly impaired by the light scattered back by the at least one lake layer in the direction of the observer that the optically variable effect becomes evident only at very specific viewing angles or with special illumination and/or luminous intensity. It has therefore proved useful if with increasing lightness L* of the at least one lake layer, the contribution of the difference between the imaginary parts of the refractive indices n 1 and n 2 increases proportionally. This means that, with the use of a dark-colored lake layer, the imaginary parts of the refractive indices of the lake layer and of the replicating layer can be relatively close together without the recognizability of the latent optically variable effect of the film being impaired from a small distance and optionally with special illumination. With the use of a light-colored lake layer, on the other hand, it has proved to be advantageous if the imaginary parts of the refractive indices of the lake layer and of the replicating layer are not so close together so that the latent optically variable effect of the film is recognizable from a small distance and optionally with special illumination.
It has proved to be useful if the contribution of the difference between the imaginary parts of the refractive indices n 1 and n 2 is in the range of 0.05 to 0.7 in the case of a lightness L* of the at least one lake layer in the range of 0 to about 50, which corresponds to a dark hue, and if the contribution of the difference between the imaginary parts of the refractive indices n 1 and n 2 is in the range of 0.3 to 0.7 in the case of a lightness L* of the at least one lake layer in the range of about 50 to 90, which corresponds to a light hue.
The relationship which is preferred for the film between the lightness L* of the lake layer and the contribution of a difference between the imaginary parts of the refractive indices n 1 and n 2 is shown by way of example in FIG. 1 .
The film may provide further security features in order further to increase its protection against forgery. Thus, it has proved to be useful if the film contains a machine-readable code. A code is preferably used in order to collate information in coded form on the film, which information can be evaluated, for example, for monitoring purposes.
Thus, for example, it is possible to encrypt the alphanumeric characters of a character legend of a motor vehicle number plate, for example in relation to the place of registration, by means of a secret encryption algorithm and use the result of this encryption as a code. In the course of a check by the police, it is then possible, for example, to determine whether the code present actually contains the motor vehicle number plate information belonging to the character legend monitored.
Security-relevant data, such as, for example, information on the holder of the motor vehicle or on the motor vehicle itself in the case of the motor vehicle number plate, can also be coded as information. As a result, the data are not accessible to the public. In the course a check by the police, the information present can then be decoded and evaluated by means of suitable apparatuses.
The machine-readable code can be provided, for example, by the diffractive relief structure and may be present, for example, in the form of a one- or a two-dimensional barcode, a microtext, etc.
The machine-readable code can additionally or alternatively also be provided by the pigmentation of the at least one lake layer, by forming said layer, for example, partly differently and/or with particular properties. Thus, an individual lake layer may have conductive pigments and/or magnetic pigments and/or luminescent pigments and/or thermochromic pigments, etc., which provide or supplement the code.
The use of a plurality of different lake layers side by side on the transparent replicating layer is readily possible. Thus, different lake layers can be used in any combination with one another. Different lake layers may contain different pigments comprising materials which have different colors or which have the same color but are otherwise distinguishable. Thus, lake layers with the same color can be distinguished by specific pigments which can be recognized only under specific conditions, such as, for example, luminescent pigments, magnetic pigments, electrically conductive pigments, thermochromic pigments, etc.
A first lake layer may have only colored pigments and a further lake layer may have the same color but additionally contain at least one specific pigment. Two lake layers having the same color may contain in each case specific pigments which differ in their properties, such as an excitation wavelength, the magnetic properties and the like.
All colored pigments which are usually used in gravure printing can be used in the at least one lake layer. These usually have a particle diameter in the range of 20 nm to 5 μm.
With the use of different lake layers, formation of demanding patterns, for example in the form of guilloches, micro inscription, symbols, logos, one- and two-dimensional bar codes and the like, is possible. These patterns may be visible under standard lumination and/or are recognizable under specific conditions, such as UV irradiation, heating, etc.
It has proved useful if, viewed perpendicularly to the plane of the transparent replicating layer, at least two different lake layers are arranged in different regions of the diffractive relief structure, which lake layers differ in their refractive indices and/or in their lightness L* and/or in their pigmentation number PN and/or in their transmittance T. As a result, it is possible to create areas, in particular pattern-like areas, in which the latent optically variable effects of the diffractive relief structure are more strongly evident than in adjacent areas on viewing close-up.
Furthermore, it has proved useful if, viewed perpendicularly to the plane of the transparent replicating layer, at least one further colored or colorless coating layer whose refractive index n 3 does not differ or differs by less than 0.05 from the refractive index n 1 of the transparent replicating layer is present at least in a region of the transparent replicating layer, in particular in a region of the diffractive relief structure. Such a colored or colorless coating layer results in complete extinction of the optically variable effect of the diffractive relief structure since the incident light is not refracted or is not refracted to a significant extent at the interface between the replicating layer and the colored or colorless coating layer.
It is therefore possible to produce films which show the latent optically variable effect only in pattern-like areas, i.e. only from area to area, although the relief structure is present everywhere. A contour of the pattern-like areas in which the latent optically variable effect is present can thereby form a further readable security feature of the film.
Alternatively, the relief structure may be present only in areas of the replicating layer in order to achieve the same effect.
The film is in particular in the form of a self-supporting laminated film or in the form of transfer film which has a substrate film and a transfer layer detachable therefrom and comprising the replicating layer and the at least one lake layer. A laminated film has in particular a transparent substrate film on which the replicating layer, the at least one lake layer and optionally an adhesive layer are arranged. If the replicating layer is self-supporting, the laminated film can, however, also comprise only the replicating layer, the at least one lake layer and optionally the adhesive layer. Substrate films are usually formed in a layer thickness in the range of 4.5 μm to 100 μm, preferably in the range of 12 μm to 50 μm.
The object is achieved for the method for the production of a film according to the invention comprising the following steps:
formation of the transparent replicating layer having the refractive index n 1 ,
formation of the diffractive relief structure on one side of the replicating layer,
formation of the at least one pigmented lake layer having the refractive index n 2 and the lightness L* on the replicating layer and directly adjacent to the diffractive relief structure by means of at least one pigmented composition, the at least one pigmented composition being applied in the flowable state and not impairing the replicating layer.
The pigmented composition is formed in particular so that it does not attack, partly dissolve or completely dissolve the replicating layer, so that the relief structure is preserved unchanged. The composition for the formation of the at least one lake layer can thus neither extinguish, round or otherwise impair the diffractive relief structure formed in the replicating layer. The profile shape of the relief structure is satisfactorily preserved.
The at least one lake layer is formed on a solidified replicating layer in which the diffractive relief structure is formed. Whether the solidification of the replicating layer is effected by a chemical curing process, by cooling or by simple drying, optionally with supply of air and/or heat, optionally with simultaneous formation of the relief structure, is not important.
Preferably, the transparent replicating layer is formed by a transparent replicating coating in the form of a thermoplastic coating, a thermally crosslinking coating or a chemically crosslinking coating, in particular a UV-crosslinking coating or a two-component coating system comprising a resin and a curing agent.
It is preferable if, for the formation of a lake layer, a pigmented composition is formed from a pigmented lake of the following composition:
0-50% by weight of water 1-10% by weight of organic solvent or solvent mixture 1-40% by weight of colored pigment(s) 0.1-5% by weight of additive for stabilizing the pigment dispersion/emulsion 0.5-10% by weight of dispersing additive 0.5-10% by weight of inorganic filler or filler mixture 25-90% by weight of polymer dispersion and/or polymer emulsion and/or polymer solution
In particular, the pigmented lake is formed with the following composition:
25-35% by of water weight 4-8% by weight of organic solvent or solvent mixture 5-10% by weight of colored pigment(s) 0.5-1% by weight of additive for stabilizing the pigment dispersion/emulsion 0.5-2% by weight of dispersing additive 0.5-3% by weight of inorganic filler or filler mixture 35-60% by weight of polymer dispersion and/or polymer emulsion and/or polymer solution
The polymer dispersion and/or polymer emulsion and/or polymer solution acts here in particular as a film former.
It has proved useful if an acrylate polymer emulsion, an acrylate copolymer emulsion or an anionic acrylate copolymer emulsion is used as the polymer emulsion.
Furthermore, it has proved useful if a polyurethane dispersion or a polyester resin dispersion or a vinyl acetate-ethylene copolymer dispersion is used as the polymer dispersion.
A water-soluble or water-dilutable urea resin, dissolved in or diluted with water, is preferably used as the polymer solution, it also being possible for the resin to be dissolved in water and organic solvent or to be diluted with water and organic solvent. However, other film-forming polymer solutions, based on water and/or based on solvent, can also be used.
In particular, the use of an emulsion or of a dispersion having a solids content of at least 30% by weight and a density d in the range of 1.01 to 1.1 g/cm 3 have proved useful.
For the formation of the pigmented lake, in particular an acrylate copolymer emulsion having a solids content of 38%, a density of 1.05 g/cm 3 and a glass transition temperature T g of about 15° C. have proved suitable as the film-former.
Alternatively, all film formers which, owing to their formulation, do not impair the replicating layer and have sufficient adhesion to the replicating layer, such as, for example, water-based systems, UV-curing systems, etc., are suitable. Solvent-based systems can also be used provided that a replicating layer is formed from a crosslinked plastic.
The use of a film according to the invention for coating motor vehicle number plates with formation of the character legend which contains alphanumeric characters is ideal.
However, the use of a film according the invention for coating packagings, plastic parts for the interior of motor vehicles, pieces of furniture and valuable documents, such as bank cards, tickets or lottery tickets, has also proved useful. In the case of bank cards, such as EC cards or credit cards, which have a magnetic stripe, the magnetic stripe is preferably formed by a film according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 6 are intended to illustrate the invention by way of example. Thus,
FIG. 1 shows a diagram of the preferred relationship between the lightness L* of a lake layer and the contribution of the difference An between the refractive indices of a replicating layer and of a lake layer, this corresponding to the difference between the imaginary parts of the refractive indices;
FIG. 2 shows a first film in cross section;
FIG. 3 shows a second film in the form of a laminated film in cross section;
FIG. 4 shows a third film in the form of a transfer film in cross section;
FIG. 5 shows a cross section Y-Y′ through a motor vehicle number plate according to FIG. 6 ; and
FIG. 6 shows a motor vehicle number plate in plan view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a diagram for the preferred relationship between the lightness L* of a lake layer and the contribution of the difference between the refractive indices An of a replicating layer and of a lake layer. In this example, the real part of the refractive index n 1 of the lake layer and of the real part of the refractive index n 2 of the replicating layer are equal, so that the real parts of the refractive indices n 1 , n 2 can be neglected and the contribution of An in the diagram gives only the difference between the imaginary parts of the refractive indices n 1 , n 2 . The lightness L* is shown for lake layers (a) to (e) comprising different colored pigments.
The letters (a) to (e) in FIG. 1 represent lake layers having different colors:
(a)=black or grey lake layer having lightness L* in the range of 0-50
(b)=blue lake layer having lightness L* in the range of 10-90
(c)=red lake layer having lightness L* in the range of 20-90
(d)=green lake layer having lightness L* in the range of 10-90
(e)=yellow lake layer having lightness L* in the range of 50-90.
The value |Δn|, i.e. the contribution of the difference between the imaginary parts of the refractive index n 1 of the replicating layer and of the refractive index n 2 of a pigmented lake layer, is preferably in the range of 0.05 to 0.7 for a black lake layer (a).
This means that, in the case of a black-pigmented lake layer, the latent optically variable effect is still recognizable even when the imaginary parts of the refractive indices of the replicating layer and lake layer differ by only 0.05. The lighter the coloring of the pigmented lake layer, the greater the chosen value |Δn| is to be so that the latent optically variable effect is still recognizable with the naked eye without problems.
This is clear from the shape of the curve |Δn| min over the lightness L* of the lake layer with a coloring of black (a) through blue (b), red (c), green (d) to yellow (e).
Thus, the curve |Δn| min increases with increasing lightness L* of the lake layer. In the case of a yellow lake layer, the value |Δn| is in the range of 0.4 to 0.7.
This means that the imaginary parts of the refractive indices of replicating layer and yellow lake layer should be chosen so that they differ by at least 0.4 in order for the latent optically variable effect to be recognizable and not to be made unrecognizable or only poorly perceptible owing to the light scattered back from the yellow lake layer in the direction of the observer.
Examples of compositions for the formation of a replicating layer and differently colored lake layers (a) to (e) are given below.
The replicating layer has been formed, for example, from a lake with the following composition (in g):
17 000 of methyl ethyl ketone 1000 of diacetone alcohol 1500 of acrylic polymer based on methyl methacrylate (density d=1.19 g/cm 3 ) 2750 of cellulose nitrate moistened with denatured ethanol, 65% (density d=1.25 g/cm 3 ) 1500 of polyisocyanate based on isophorone diisocyanate
Lake for the Formation of a Black Lake Layer (a) With Minimum Pigmentation (in g):
2500 of water 2500 of organic solvent isopropyl alcohol 200 of basic additive, 25% in water (volatile) 400 of dispersing additive, solids: 40% 200 of silicon dioxide filler, mean particle size: 16 nm 100 of silicon dioxide filler, mean particle size: 7.5 μm 50 of carbon black pigment, density d=1.8 g/cm 3 , ON=230 2500 of binder I: acrylate copolymer emulsion, solids: 37.5% 4000 of binder II: acrylate copolymer emulsion, solids: 55%
The following is applicable to this black lake:
P N = ∑ i x ( m P × f ) x ( m B M + m A ) = 50 g × 127.8 cm 3 g 3137.5 g + 160 g = 1.9 cm 3 g
where m P =50 g of carbon black
f=ON/d=230/1.8 g/cm 3 =127.8 cm 3 /g (for carbon black) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =0.4·400 g of dispersing additive=160 g of solids of the dispersing additive
Lake for the Formation of a Black Lake Layer (a) With Maximum Pigmentation (in g):
2500 of water 2500 of organic solvent isopropyl alcohol 200 of basic additive, 25% in water (volatile) 400 of dispersing additive, solids: 40% 200 of silicon dioxide filler, mean particle size: 16 nm 100 of silicon dioxide filler, mean particle size: 7.5 μm 2500 of carbon black pigment, density d=1.8 g/cm 3 , ON=230 2500 of binder I: acrylate copolymer emulsion, solids: 37.5%
4000 of binder II: acrylate copolymer emulsion, solids: 55%
The following is applicable to this black lake:
P N = ∑ 1 x ( m P × f ) x ( m B M + m A ) = 2500 g × 127.8 cm 3 g 3137.5 g + 160 g = 96.9
where m P =2500 g of carbon black
f=ON/d=230/1.8 g/cm 3 =127.8 cm 3 /g (for carbon black) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 k of dispersing additive)=160 g of solids of the dispersing additive
Lake for the Formation of a Blue Lake Layer (b) (in g):
L*= 33.58 a*= 0.54 b*=− 30.23
2500 of water 2500 of organic solvent isopropyl alcohol 200 of basic additive, 25% in water (volatile) 400 of dispersing additive, solids: 40% 200 of silicon dioxide filler, mean particle size: 16 nm 100 of silicon dioxide filler, mean particle size: 7.5 μm 1200 of phthalocyanine blue pigment, density d=1.5 g/cm 3 , ON=43 2500 of binder I: acrylate copolymer emulsion, solids: 37.5% 4000 of binder II: acrylate copolymer emulsion, solids: 55%
The following is applicable to this blue lake:
P N = ∑ 1 x ( m P × f ) x ( m B M + m A ) = 1200 g × 28.7 cm 3 g 3137.5 g + 160 g = 10.4
where m P =1200 g of phthalocyanine blue pigment
f=ON/d=43/1.5 g/cm 3 =28.7 cm 3 /g (for phthalocyanine blue pigment) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 g of dispersing additive)=160 g of solids of the dispersing additive
Lake for the Formation of a Red Lake Layer (c) (in g):
L*= 38.43 a*= 44.23 b*= 20.44
2500 of water 2500 of organic solvent isopropyl alcohol 200 of basic additive, 25% in water (volatile) 400 of dispersing additive, solids: 40% 200 of silicon dioxide filler, mean particle size: 16 nm 100 of silicon dioxide filler, mean particle size: 7.5 μm 1200 of diketopyrrolopyrrole pigment, density d=1.35 g/cm 3 , ON=49 2500 of binder I: acrylate copolymer emulsion, solids: 37.5% 4000 of binder II: acrylate copolymer emulsion, solids: 55%
The following is applicable to this red lake:
P N = ∑ 1 x ( m P × f ) x ( m B M + m A ) = 1200 g × 36.3 cm 3 g 3137.5 g + 160 g = 13.2 cm 3 g
where m P =1200 g of diketopyrrolopyrrole pigment
f=ON/d=49/1.35 g/cm 3 =36.3 cm 3 /g (for diketopyrrolopyrrole pigment) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 g of dispersing additive)=160 g of solids of the dispersing additive
Lake for the Formation of a Dark Green Lake Layer (d) (in g)
L*= 14.52 a*=− 49.34 b*= 10.91
2500 of water 2500 of organic solvent isopropyl alcohol 200 of basic additive, 25% in water (volatile) 400 of dispersing additive, solids: 40% 200 of silicon dioxide filler, mean particle size: 16 nm 100 of silicon dioxide filler, mean particle size: 7.5 μm 1200 of chlorinated copper phthalocyanine pigment, density d=2.03 g/cm 3 , ON=30 2500 of binder I: acrylate copolymer emulsion, solids: 37.5% 4000 of binder II: acrylate copolymer emulsion, solids: 55%
The following is applicable to this dark green lake:
P N = ∑ 1 x ( m P × f ) x ( m B M + m A ) = 1200 g × 14.8 cm 3 g 3137.5 g + 160 g = 5.4 cm 3 g
where m P =1200 g of chlorinated copper phthalocyanine pigment
f=ON/d=30/2.03 g/cm 3 =14.8 cm 3 /g (for chlorinated copper phthalocyanine pigment) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 g of dispersing additive)=160 g of solids of the dispersing additive
Lake for the Formation of a Yellow Lake Layer (e) (in g):
L*= 86.35 a*= 1.91 b*= 89.79
2500 of water 2500 of organic solvent isopropyl alcohol 200 of basic additive, 25% in water (volatile) 400 of dispersing additive, solids: 40% 200 of silicon dioxide filler, mean particle size: 16 nm 100 of silicon dioxide filler, mean particle size: 7.5 μm 1200 of monoazo-benzimidazolone pigment, density d=1.57 g/cm 3 , ON=56 2500 of binder I: acrylate copolymer emulsion, solids: 37.5% 4000 of binder II: acrylate copolymer emulsion, solids: 55%
The following is applicable to this yellow lake:
P N = ∑ 1 x ( m P × f ) x ( m B M + m A ) = 1200 g × 35.7 cm 3 g 3137.5 g + 160 g = 13 cm 3 g
where m P =1200 g of monoazo-benzimidazolone pigment
f=ON/d=56/1.57 g/cm 3 =35.7 cm 3 /g (for monoazo-benzimidazolone pigment) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 g of dispersing additive)=160 g of solids of the dispersing additive
FIG. 2 shows a first film 1 in cross section, which has a transparent replicating layer 2 having a diffractive relief structure 3 and a colored lake layer 4 . The lake layer 4 is directly adjacent to that side of the replicating layer 2 on which the diffractive relief structure 3 is present. The replicating layer 2 has a layer thickness of 0.5 μm, while the lake layer has a layer thickness of 3 μm.
Here, the replicating layer 2 is thermoplastic and has been formed from a coating of the following composition already mentioned above (in g):
17 000 of methyl ethyl ketone 1000 of diacetone alcohol 1500 of acrylic polymer based on methyl methacrylate (density d=1.19 g/cm 3 ) 2750 of cellulose nitrate moistened with denatured ethanol, 65% (density d=1.25 g/cm 3 ) 1500 of polyisocyanate based on isophorone diisocyanate
The diffractive relief structure 3 has been stamped in the form of a linear grating having a sinusoidal profile and a spatial frequency of 1000 lines/mm into the replicating layer 2 by means of a heated, profiled tool.
Here, the lake layer 4 has been formed from a black lake of the following composition (in g);
2500 of water 2500 of organic solvent isopropyl alcohol 200 of basic additive, 25% by weight in water (volatile) 400 of dispersing additive, solids: 40% by weight 200 of silicon dioxide filler (mean particle size: 16 nm) 100 of silicon dioxide filler (mean particle size: 7.5 nm) 1000 of carbon black pigment, density d=1.8 g/cm 3 , oil number ON=230 2500 of binder I (acrylate copolymer emulsion, solids: 37.5% by weight) 4000 of binder II (acrylate copolymer emulsion, solids: 55% by weight)
The following is applicable to this black lake:
P N = ∑ 1 x ( m P × f ) x ( m B M + m A ) = 1000 g × 127.8 cm 3 g 3137.5 g + 160 g = 38.7 cm 3 g
where m P =1000 g of carbon black
f=ON/d=230/1.8 g/cm 3 =127.8 cm 3 /g (for carbon black) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 g of dispersing additive)=160 g of solids of the dispersing additive
When the film 1 is viewed on the sides of the replicating layer 2 , a latent optically variable effect is seen.
FIG. 3 shows a second film 1 ′ in the form of a laminated film in cross section. The laminated film has a self-supporting transparent substrate film 10 comprising PET in a film thickness of 19 μm, adjacent to this the replicating layer 2 having the diffractive relief structure 3 and furthermore the lake layer 4 . The replicating layer 2 and the lake layer 4 are formed as described in FIG. 2 . The laminated film is applied to a substrate, not shown here, in such a way that the lake layer 4 is bonded to the substrate, in particular by means of an adhesive layer. The adhesive layer can be applied to the substrate and/or to the lake layer 4 . The substrate film 10 is permanently bonded to the replicating layer 2 and remains as a protective layer over the replicating layer 2 and the lake layer 4 on the substrate. When the film 1 ′ is viewed on the sides of the substrate film 10 , a latent optically variable effect is seen.
FIG. 4 shows a third film 1 ″ in the form of a transfer film in cross section. The transfer film has a substrate film 11 detachable from a transfer layer and comprising PET and having a layer thickness of 19 μm.
Arranged between the transfer layer and the detachable substrate film 11 is optionally a release layer 6 which permits or promotes separation of substrate film 11 and transfer layer. Such a release layer 6 is usually formed from wax, silicone or the like and frequently has a layer thickness in the range of 1 nm to 1.5 μm, in particular in the range of 4 nm to 12 nm.
Furthermore, a protective lacquer layer, for example having a layer thickness in the range of 0.5 μm to 15 μm, in particular in the range of 1 μm to 3 μm, can be arranged between the detachable substrate film 11 and the transfer layer or between the release layer 6 and the transfer layer, which protective lacquer layer remains on the transfer layer after detachment of the substrate film 11 and protects the surface thereof from mechanical and/or chemical attacks.
Such a protective lacquer layer may be formed, for example, from a lacquer of the following composition (in g):
2200 of methyl ethyl ketone 300 of butanol 1500 of acrylic polymer based on methyl methacrylate 30 of UV absorber 10 of light stabilizer 120 of feldspar, density d=2.6 g/m 3
The transfer layer of the transfer film according to FIG. 4 thus comprises, in this sequence, an optional protective lacquer layer, the replicating layer 2 , the lake layer 4 and an adhesive layer 5 which is arranged on that side of the lake layer 4 which faces away from the substrate film 11 . This may be a hotmelt adhesive layer or a cold adhesive layer. The adhesive layer 5 has in particular a layer thickness in the range of 0.2 to 10 μm, preferably in the range of 1 to 2.5 μm.
The transfer film according to FIG. 4 is arranged on a substrate so that the adhesive layer 5 faces the substrate. Thereafter, the adhesive of the adhesive layer 5 is activated and is bonded to the substrate. This can be effected over the whole area or only in regions, so that the transfer layer is adhering to the substrate completely or only in regions when the substrate film 11 is peeled off. If the transfer layer of the transfer film is transferred only in regions to a substrate, those regions of the transfer layer which are not fixed to the substrate by means of the adhesive layer 5 remain on the substrate film 11 and are removed with it.
FIG. 5 shows a first film according to FIG. 2 , applied to a substrate 7 in the form of a motor vehicle number plate 100 , in cross section Y-Y′ (cf. FIG. 6 ). The lake layer 4 is permanently adhesively bonded to the substrate 7 .
FIG. 6 shows the motor vehicle number plate 100 from FIG. 5 in plan view. The motor vehicle number plate consists of a support plate 101 which is provided with a white, retroreflective coating and usually consisting of an aluminum or steel sheet. A raised character legend 102 is stamped into the support plate 101 by means of a mechanical stamping process. The character legend 102 consists of alphanumeric characters 102 a , 102 b , 102 c , 102 d , which, for example in Germany, indicate the place of registration of the motor vehicle and form an individual number. In order to make the character legend 102 of the stamped motor vehicle number plate 100 readily visible, the raised stamped regions are coated in color with a black film having a latent optically variable effect, the presence of which is indicated by the dotted white lines. A stamped raised border 103 of the motor vehicle number plate 100 , which is likewise coated with the black film having a latent optically variable effect, is furthermore provided. For this purpose, an appropriate transfer of colored film is carried out by means of a transfer film which consists of a substrate film and a transfer layer detachable therefrom, as described, for example, in FIG. 4 . In the case of the transfer of the transfer layer in regions, the transfer film is brought into mechanical contact with the raised stamped regions of the support plate 101 of the motor vehicle number plate 100 and the transfer layer is transferred in the exact position to the raised regions under pressure, optionally also under pressure and at elevated temperature.
However, other fields of use for the film, as described above, for example on surfaces of pieces of furniture, valuable documents, motor vehicle interior parts and the like, are of course also advantageous. | A film ( 1 ) which includes at least one transparent replicating layer ( 2 ) having a diffractive relief structure ( 3 ) and a reflective layer, the reflective layer being formed by at least one pigmented lake layer ( 4 ), and the film ( 1, 1′, 1 ″) showing a latent optically variable effect produced by the diffractive relief structure ( 3 ), and the use thereof. Further a method for the production of such a film. | 1 |
TECHNICAL FIELD
The present invention relates to a fireproofing system for standard cable trays particularly those which carry powered cables and/or control cables in nuclear power plants.
One of the most critical aspects of fire protection in nuclear power plants is the assurance that safe shutdown can be accomplished. It is therefore imperative that the fire protection system incorporate features which are capable of limiting fire damage to insure that at least one train of systems (cable trays) necessary to achieve and maintain hot shutdown conditions from either the control room or emergency control station(s) is free of fire damage and that those systems necessary to achieve and maintain cold shutdown from either the control room or emergency control station(s) can be repaired within 72 hours.
In an effort to meet these objectives, redundant trains have been incorporated into the operating systems of nuclear power plants. However, in many existing nuclear power plants, these redundant trains of systems necessary to achieve and maintain hot shutdown conditions are located within the same fire area, usually the cable spreading room, outside of primary confinement. Because these redundant trains are located in the same fire area, a fire could readily threaten the essential operation of all the redundant trains and thus prevent safe shutdown.
In recognition of this serious threat, Appendix R of the Nuclear Regulatory Commission Fire Protection Program for Operating Nuclear Power Plants (10 CFR Part 50) mandates one of the following means for insuring that one of the redundant trains will be free of fire damage:
A. Separation of cables and equipment and associated non-safety circuits of redundant trains by a fire barrier having a 3-hour rating. Structural steel forming a part of or supporting such fire barriers shall be protected to provide fire resistance equivalent to that required of the barrier.
B. Separation of cables and equipment and associated non-safety circuits of redundant trains by a horizontal distance of more than 20 feet with no intervening combustible or fire hazards. In addition, fire detectors and an automatic fire suppression system shall be installed in the fire area; or
C. Enclosure of cable and equipment and associated non-safety circuits of one redundant train in a fire barrier having a 1-hour rating. In addition, fire detectors and an automatic fire suppression system shall be installed in the fire area.
The most practical solution to protect redundant trains within the same fire area will, in many situations, be option C above.
While many existing nuclear power plants may have a horizontal separation of 20 feet or more between redundant trains (option B), control of transient combustibles within the intervening distance is difficult to realize in practice. The mandated fire protection is therefore threatened with the potential that safe shutdown may not be achieved.
BACKGROUND ART
Many investigators have attempted to provide fire protection for cable trays. U.S. Pat. No. 4,194,521 relates to a corruguated structure coated with an intumescent material, said structure being used as a tray for supporting insulated electrical cables. This structure is located beneath the cables and will only provide fire protection if the fire starts below the assembly. No fire protection is provided for the sides or top of the cable tray.
Another attempt to provide more fire protection for cables is shown in U.S. Pat. No. 4,276,332 which relates to a fireproof cable tray which completely surrounds the cables. The major disadvantages of this system are its inability to fit around an existing metal cable tray since it is designed to function as the cable tray and, most importantly, its inability to dissipate the heat build-up from resistance loss as power runs through the cables. The predominant reason for supporting cables in trays suspended above the floor is to allow air flow around them for cooling. However, if the tray itself is surrounded by inorganic fiber insulation, heat from the cable will not be dissipated to the surroundings and the cables must be derated. This heat build-up, if allowed to remain unchecked, could also cause a cable tray fire.
U.S. Pat. No. 4,064,359 discloses insulation materials for protecting electrical cables, cable trays or conduits from fire. However, the inherent disadvantage of cable temperature build-up under normal operating conditions still remains a serious problem.
U.S. Pat. No. 4,069,075 relates to intumescent coating materials for structural members and particularly a wire mesh attached to a structural member with a self-adhering char-forming intumescent coating applied thereover and to the structural member.
DISCLOSURE OF INVENTION
The present invention provides a fire protected cable tray assembly which will provide one-hour fire protection and at the same time avoids cable derating.
The invention also provides a system which can be easily installed around existing cable trays and is structurally sound.
Another aspect of the present invention relates to means for mechanically joining sections of the fire-proofing system together which will withstand a one-hour fire rating test.
The fireproofing system for cable trays of the present invention comprises an intumescent fire retardant composite sheet material, such as that described in U.S. Pat. No. 4,273,879, having laminated on one major surface thereof a galvanized steel base layer, a wire netting laminated to the other major surface of the composite sheet material and an aluminum foil layer applied over the wire netting. The resulting composite provides a fire retardant sheet material which can be cut and bent into many unique shapes to fit around a cable tray.
The advantage of this intumescent material is its ability to remain in a dense, unexpanded, noninsulating form until exposed to heat or flame at which time it would expand volumetrically up to 8 times to provide an insulating char in sheet form. The aluminum foil is instrumental in directionalizing the expansion of the intumescent material in a direction substantially perpendicular to the plane of the foil layer and the wire netting serves to unify the thus formed insulating char. The unexpanded sheet has a thermal conductivity of 1.56 BTU/in./hr./ft. 2 /°F. at 95° F.; essentially it is a fair conductor of heat and will allow cable heat dissipation. After expansion, the composite sheet becomes an excellent insulator with a thermal conductivity of 0.35 BTU/in./hr./ft. 2 /°F. at 95° F.
The excellent heat dissipation property of the composite sheet was shown when heat dissipation measurements were made on the fireproofing system of the present invention versus a ceramic fiber blanket wrapped system. The temperatures on the outside surface of the cable tray and the inside air were measured as a function of varying amounts of heat (watts/ft.) applied inside each system. Even better heat dissipation was obtained when the top cover panel was perfoated with 1/4 inch diameter holes spaced 2 inches apart in all directions. These holes will be effectively sealed off after shot exposure to heat.
Cable tray fire barriers fail in one of two general modes: heat transmission or mechanical failure. Of these, mechanical failures predominate. Frequently, fasteners or support systems fail and permit rapid heat transmission to the interior of the cable tray. This mechanical failure problem has been eliminated in the present invention through the use of unique joining channels. These channels permit obtaining a structurally sound, fireproof joint.
BRIEF DESCRIPTION OF DRAWINGS
The present invention will become more apparent from the following detailed description and the accompanying drawings in which:
FIG. 1 is a perspective view of the intumescent composite sheet of the present invention viewed with the aluminum foil layer uppermost;
FIG. 2 is a sectional view of the intumescent composite sheet of FIG. 1;
FIG. 3 is a sectional view of a C-channel joining member constructed from the intumescent composite sheet of FIGS. 1 and 2, with the galvanized steel base layer innermost;
FIG. 4 is a sectional view of an H-channel joining member and shows two intumescent composite sheets of FIGS. 1 and 2 being joined together;
FIG. 5 is a sectional view of a right angle-channel joining member;
FIG. 6 is a perspective view of a conventional cable tray loaded with cables;
FIG. 7 is a sectional view of a U-shaped bent member of intumescent composite sheet for attachment to the cable tray shown in FIG. 6;
FIG. 8 is a perspective view showing a portion of a cable tray protection system of the present invention around the cable tray of FIG. 6 and utilizing C-channel joining members of FIG. 3;
FIG. 9 is a sectional view of the cable tray protection system of FIG. 8;
FIG. 10 is a sectional view showing a cable tray protection system constructed without the joining channel members;
FIG. 11 is a perspective bottom view, partly in section, of a channelled plate joining member and shows two intumescent composite sheets of FIGS. 1 and 2 being joined together;
FIG. 12 is a graph showing the heat dissipation characteristics of three cable tray protection systems;
FIG. 13 is a sectional view of another embodiment of a cable tray protection system of the present invention; and
FIG. 14 is a sectional view showing two intumescent composite sheets of FIGS. 1 and 2 being joined together.
DETAILED DESCRIPTION OF THE INVENTION
The intumescent composite sheet 10 shown in FIGS. 1 and 2 comprises a flexible, heat expanding, fire retardant composite sheet 11 having an intumescent component in granular form, an organic binder such as an elastomer, an organic char-forming component and fillers such as clay, silica, synthetic organic staple fibers or inorganic fibers such as fiberglass or ceramic fibers, as more fully described in U.S. Pat. No. 4,273,879, which patent is incorporated herein by reference. A galvanized steel base layer 12, 0.005 to 0.025 inch thick, is laminated to one surface of said fire retardant composite sheet 11 and a hexagonal wire netting 13 is bonded to the other surface of the fire retardant composite sheet 11. An aluminum foil 14, 0.002 to 0.005 inch thick, is then bonded over the wire netting 13 to produce composite sheet 10. Due to the physical nature of composite sheet 10, particularly the galvanized steel base layer 12, the sheet can be bent into desired shapes such as the C-channel joining member 15 of FIG. 3, the H-channel joining member 20 of FIG. 4, the right angle-channel joining member 25 of FIG. 5 or the U-shaped bent member 30 of FIG. 7.
EXAMPLE 1
A conventional cable tray 35 consisting of parallel side rails 36 and spaced cross members 37 fitted between the side rails 36 with cables 38 resting on cross member 37 was protected from fire using a bent member 30 as the bottom and side portions and a flat composite sheet 50 as the top portion. C-channel joining member 15 was used to unify and protect the joint between the top and side portions. As shown in FIG. 3, C-channel joining member 15 is formed by bending a strip of flat composite sheet 10 into an elongate C-shaped form. As can be seen in FIG. 9, the dimensions of C-channel joining member 15 are such that two thicknesses of flat composite sheet 10 can be accommodated within the throat of the C. The cable tray protection system was also provided with hanging clips 51 on bent member 30 to allow the system to be attached as by hanging onto the cable tray 35. Self tapping screws 52 joined C-channel joining member 15 to the top member 50 and bent member 30. This assembly was fire tested using a small scale Fire Test Furnace generally following ASTM E-119 time-temperature fire curve. This system was fire tested successfully for one hour. The system was loaded with neoprene covered cables 38 and cable temperature and insulation resistivity were measured during the one-hour fire test. Insulation resistivity is measured in megohms and is an indication of the condition of the cable insulation. If the cable insulation resistivity drops to less than 1 megohm, a cable short is expected and is considered a failure. Normal resistivity typically is infinity. Average values obtained on this test are shown in Table 1.
TABLE 1______________________________________ Tray Re-Time E-119 Furnace Rung Metal Cable sistance -(min.) (°F.) (. degree.F.) (°F.) (.degree .F.) (°F.) megohms______________________________________05 1000 962 70 177/125 68 ∞10 1300 1696 94 218/205 78 "15 1399 1512 119 226/241 89 "20 1462 1442 141 229/247 99 "25 1510 1614 154 234/252 109 "30 1550 1487 168 246/261 118 "35 1581 1438 188 276/316 129 "40 1613 1527 219 335/455 142 "45 1633 1643 269 406/598 168 "50 1661 1646 342 470/668 212 "55 1681 1622 442 518/714 274 "60 1700 1684 535 552/747 345 1000______________________________________
EXAMPLE 2
To show the importance of proper jointing, a cable tray protection system was constructed with similar materials as Example 1 but without C-channel joining members 15. A modified bent member 31 and top member 50 were screwed together using self tapping screws 52 as shon in FIG. 10. A strip of aluminum foil tape 53 covered each corner of the joint. A fire test was run in the small scale Fire Test Furnace as in Example 1. After 35 minutes, the interior air temperature was high enough to self-ignite the cable insulation and the test was stopped. After the assembly had cooled, examination showed that the fire retardant composite sheet around the joining seam had split open on both sides, exposing the metal to flame. The time-temperature data for this test are shown in Table 2.
TABLE 2______________________________________Time E-119 Furnace Tray Air Metal Cable(min.) (°F.) (°F.) (°F.) (°F.) (°F.) (°F.)______________________________________ 0 68 71 5 1000 770 80 100 191 7010 1300 1384 108 134 241 8415 1399 1439 136 153 260 9820 1462 1461 161 183 274 117*25 1510 1486 228 325 451 18830 1550 1507 381 481 733 31835 1581 1556 547 586 809 43640 161345 163350 166155 168160 1700______________________________________ *A rapid temperature rise inside of the system took place after 20 minutes.
EXAMPLE 3
Two fire protected cable tray sections each consisting of a bent member 30 and top member 50 unified with C-channel joining members 15 as in Example 1 were joined together using H-channel joining members 20. H-channel joining member 20 is fabricated by joining two U-shaped sheet metal members together. The joining is suitably accomplished by juxtaposing the bottoms 21 of the two U-shaped members and spot welding them together as shown in FIG. 4. A strip 24 of flat composite sheet 10 is affixed to and covers one surface of H-channel joining member 20. This strip 24 serves to prevent heat transmission through the sheet metal of the H-channel joining member 20 into the interior of the cable tray. As shown in FIG. 4, the two top members 50 (and similarly the horizontal bottom portions of bent members 30) were joined by being inserted into the slots 23 formed by the legs 22 of the H-channel joining member 20. Appropriately sized (shorter) H-channel joining members 20 were used to join the sides of the bent members 30. This configuration of two fire protected cable tray sections joined together using H-channel joining members 20 was fire tested in the small scale Fire Test Furnace using the ASTM E-119 time-temperature fire curve procedure in Example 1. This system was fired successfully for one hour. Average values obtained on this test are shown in Table 3.
TABLE 3______________________________________Time Temperature (°F.)Mins. Bottom Side Top Tray Air Furnace E-119______________________________________05 123 150 109 70 70 756 100010 192 210 221 77 78 1175 130015 288 237 260 79 95 1490 139920 232 253 271 96 109 1366 146225 242 267 305 102 118 1324 151030 253 300 282 105 126 1500 155035 286 346 212 142 140 1582 158140 354 409 340 178 173 1568 161345 441 426 415 197 219 1540 163350 504 457 466 229 264 1531 166155 603 500 520 268 303 1577 168160 651 530 540 284 337 1564 1700______________________________________
The cable tray protection system was examined after the test. The char was excellent and no cracks were evident. The C-channel joining members 15 and the H-channel joining members 20 performed well in holding the sections together and eliminating smoke or flame penetration. The fire barrier metal temperature ranged from 530°-651° F. after 60 minutes. The air temperature was 337° F. after 60 minutes. This air temperature would not ignite IEEE 383 type cables.
EXAMPLE 4
The right angle-channel joining member 25 illustrated in FIG. 5 is designed to be used in joining cable tray sections at right angles to each other such as when the cable tray run makes a 90° turn. The right angle-channel joining member 25 is fabricated from two U-shaped sheet metal members 26 with their bottoms joined together perpendicularly and fastened as by spot welding as shown in FIG. 5. A strip 27 of flat composite sheet 10 is fastened as by rivets to the outer surface of the right angle-channel joining member 25 when the joining member is to be used on the outer edge of the joint. The strip 27 would be placed on the inner surface of the right angle-channel joining member for use on the inner edge of the joint. As in the H-channel joining member, flat sheets of composite sheet would be inserted into the slots 29 formed by the legs 28 of the joining member.
EXAMPLE 5
Another example of a joining technique would be to use the joining plate 55 shown in FIG. 11 to join two cable tray protection system sections. Joining plate 55 comprises a flat plate 56 bisected by a central U-shaped recess 57 within which a strip 58 of fire retardant composite sheet 11 faced on both surfaces with aluminum foil is inserted to provide thermal insulation. As shown in FIG. 11, joining plate 55 is attached along one longitudinal edge to a top member 50 as with screws 59 and placed onto cable tray 35. S-clips 60 are fastened onto the adjoining top member 50 at spaced intervals with self-tapping screws 61 after which top member 50 would be placed onto cable tray 35 and S-clips 60 would be slipped onto the other longitudinal edge of joining plate 55 where they would be frictionally held in place. A fire test of a modified joint utilizing joining plate 55 was successfully run in the small scale Fire Test Furnace as in Example 1. In this modified joint, the two top members 50 were both riveted to joining plate 55 and S-clips 60 were not used. The system was loaded with three neoprene covered cables and cable temperature and insulation resistivity were measured during the 1 hour test. Average values obtained for this test are shown in Table 4.
TABLE 4______________________________________Temperature (°F.)Time CableMins. Furnace Seam Bottom Tray Air Cable______________________________________05 1221 170 187 76 97 7310 1455 213 209 87 113 8115 1521 230 210 96 122 8920 1678 233 203 104 130 9625 1491 233 218 111 141 10530 1546 266 334 127 173 11735 1565 349 421 156 218 14340 1566 440 473 195 273 18545 1569 555 527 243 330 24250 1582 618 577 285 393 29855 1676 678 633 330 434 35160 1701 733 683 385 487 404______________________________________
Cable resistance results showed 1000+ megohms for the full 60 minutes of the test run.
FIG. 12 graphically illustrates the efficacy of the cable tray protection system of the present invention in heat dissipation. Curve A o shows the outside surface temperature of a cable tray with the cable tray protection system of the present invention installed thereon and with a perforated top member 50. Curve A I shows the interior air temperature of the same cable tray measured immediately below top member 50. Curves B o and B I show the temperatures of a cable tray with the cable tray protection system of the present invention but without perforations in the top member 50. Curves C o and C I show the temperatures of a cable tray having a ceramic fiber blanket wrapped around the exterior surfaces of the cable tray.
EXAMPLE 6
A cable tray 35 with cables 38 was protected from fire using bent side members 54 formed from composite sheet 10 and fastened to top and bottom members 50 also formed from composite sheet 10, as shown in FIG. 13. All of these members were fastened together using self tapping screws 52. The joints between the top and side members and bottom and side members were similarly protected by being overlayed with an inorganic intumescent mat 72 comprised of ceramic fibers and unexpanded vermiculite, as more fully described in U.S. Pat. Nos. 3,916,057 and 4,305,992, which patents are incorporated herein by reference. The intumescent mat material will expand up to three times its initial volume upon the application of heat. A wire netting (hardware cloth) 71 with 0.5 inch square welded openings was placed over the intumescent mat to hold it together during expansion. A hardware cloth was attached using oversized washers 70 and self tapping screws 52.
EXAMPLE 7
Two fire protected cable tray sections were joined together as shown in FIG. 14. As in Example 3, the joints were located on the interior (metal side) of the composite sheets of the cable tray protection system and were required for joining the top, bottom and two side members. A piece of sheet metal was bent into a C-shaped joining channel 73 and a strip of intumescent mat 72 was placed within the channel 73. The two adjoining top members 50 were abutted together and fastened to the C-shaped joining channel 73 using self tapping screws 52. The bottom and two sides of the cable tray protection system were joined in a similar manner. The outer (fire side) of the joint was protected using a strip of intumescent mat 72 held in place with 0.5 inch hardware cloth. The system was fire tested in a small scale Fire Test Furnace as in Example 1. The system was loaded with three neoprene covered cables and air and metal temperatures and cable insulation resistivity were measured during the 1 hour fire test. Average values obtained for this test are shown in Table 5.
TABLE 5______________________________________ Temperature °F. ResistanceTime (mins.) Furnace Air Metal Megohm______________________________________05 1500 75 175 ∞10 1425 110 210 "15 1430 140 230 "20 1575 150 240 "25 1720 160 245 "30 1650 165 250 "35 1550 175 265 "40 1560 10 280 "45 1625 250 320 "50 1700 300 400 "55 1675 350 490 "60 1650 395 590 1000______________________________________
After the test, the cables were examined and no cracks or breaks were observed. A strong one hour protection was obtained.
It will be readily apparent that various modifications of the invention are possible and will readily suggest themselves to those skilled in the art and are contemplated. | A fire protection system for installation about the periphery of a cable tray consisting of parallel side rails and spaced cross members fitted between the side rails and comprising heat expanding, fire retardant composite sheet material joined together to form a protective enclosure around the cable tray and means for mechanically joining sections of the fire protection system are disclosed. | 7 |
FIELD
The present disclosure relates to differentials for motor vehicles and more particularly to differentials for motor vehicles having integrated torque vectoring.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.
In recent years, motor vehicles, especially passenger cars and light trucks, have been the subject of intense effort to improve handling performance in both routine and emergency driving conditions. While the emphasis has been on the latter, it has been accompanied by the realization that aggressive, active control systems can prevent a routine or substantially routine driving condition from escalating into an emergency situation.
Accordingly, traction control and torque distribution powertrain systems have been developed concurrently with anti-lock brake systems (ABS) and other vehicular safety systems. Generally speaking, traction control and torque distribution powertrain systems encompass controlled mechanical, electro-mechanical or hydro-mechanical systems which control both the generation of torque by controlling operational aspects of the prime mover or the distribution of torque to the two or four driving wheels of the vehicle by controlling transmission, transfer case and differential components.
SUMMARY
The present invention provides a differential for a motor vehicle powertrain having integrated torque vectoring. The differential of the present invention provides vehicle handling enhancement in vehicle systems often referred to as stability control systems. The differential of the present invention includes a pair of side-by-side planetary gear assemblies having a common planet gear carrier which is driven by the output of a transmission. Each of the planetary gear assemblies include a ring gear that may be individually and selectively grounded (braked) to a stationary differential housing by a respective friction brake and a sun gear that is coupled through an axle to a respective drive wheel. Each planetary gear assembly includes elongated planet gears which mesh not only with their respective sun and ring gears but also with the planet gears of the other planetary gear assembly. Selective activation of the brakes controls the distribution, i.e., vectoring, of torque to each of the drive wheels. The differential also includes an optional limited slip clutch disposed between a sun gear and a ring gear of one of the planetary gear assemblies.
Thus it is an aspect of the present invention to provide a torque vectoring differential having a pair of planetary gear assemblies disposed side-by-side.
It is a further aspect of the present invention to provide a torque vectoring differential having a pair of independently operable brakes operably disposed between a respective ring gear of the pair of planetary gear assemblies and ground.
It is a still further aspect of the present invention to provide a torque vectoring differential having elongated planet gears which mesh not only with their associated sun and ring gears but also with the planet gears of the other planetary gear assembly.
It is a still further aspect of the present invention to provide a torque vectoring differential having an optional clutch disposed between the ring and sun gears of a planetary gear assembly for limiting slip of the differential.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 is a lever diagram of a torque vectoring differential according to the present invention;
FIG. 2 is a diagrammatic view of a torque vectoring differential according to the present invention and associated components of a motor vehicle; and
FIG. 3 is a side elevational view of the planetary gear assemblies of a torque vectoring differential according to the present invention.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
With reference now to FIG. 1 , a torque vectoring differential for a motor vehicle according to the present invention is illustrated in a lever diagram and designated by the reference number 10 . A lever diagram is a schematic representation of the components of a device such as a differential or an automatic transmission wherein a planetary gear assembly is represented by a vertical bar or lever and the components of the planetary gear assembly such as the sun gear, the planet gear carrier and the ring gear are represented by nodes. The relative lengths of the vertical bars between the nodes represent the ratios between the components. Mechanical couplings or interconnections between the nodes such as shafts or quills are represented by horizontal lines and torque transmitting devices such as friction clutches and brakes are represented by interleaved or nested fingers. Further explanation of the format, purpose and use of lever diagrams can be found in SAE Paper No. 810102 entitled, “The Lever Analogy: A New Tool in Transmission Analysis” by Benford and Leising which is fully incorporated herein by reference.
The torque vectoring differential 10 includes an input shaft 12 , a first or left output half shaft or axle 14 , a second or right output half shaft or axle 16 and a stationary housing 18 which is referred to in reference to FIG. 1 as ground. The single five node lever 20 represents two planetary gear assemblies 30 and 50 . A first or left planetary gear assembly 30 includes a first node 32 which is connected to and drives the first or left output half shaft or axle 14 , a second node 34 which is connected to and driven by the input shaft 12 and a third node 36 . A second or right planetary gear assembly 50 includes a first node 52 which is connected to and drives the second or right output half shaft or axle 16 , a second node 54 which is common with the second node 34 of the first planetary gear assembly 30 and which is connected to and driven by the input shaft 12 and a third node 56 .
The third node 36 of the first or left planetary gear assembly 30 is coupled to one side, for example an input side, of a first or left friction brake assembly 38 and the other side of the first or left friction brake assembly 38 is connected to ground 18 . The third node 56 of the second or right planetary gear assembly 50 is coupled to one side, for example an input side, of a second or right friction brake assembly 58 and the other side of the second or right friction brake assembly 58 is connected to ground 18 .
Referring now to FIGS. 2 and 3 , the torque vectoring differential 10 includes the input shaft 12 which is connected to and drives a common planet gear carrier 34 , 54 . The first or left output half shaft or axle 14 is coupled to and driven by a first or left sun gear 32 of the first of left planetary gear assembly 30 and the second or right output half shaft or axle 16 is coupled to and driven by a second or right sun gear 52 of the second or right planetary gear assembly 50 . The first or left planetary gear assembly 30 also includes a first or left ring gear 36 which is connected to the input side of the first or left friction brake assembly 38 having a plurality of input friction plates or discs 40 . Interleaved with the plurality of input plates or discs 40 and connected to ground or the housing 18 are a plurality of stationary or ground plates or discs 42 . A first or left operator or actuator 44 is disposed in proximate, operable relationship to the interleaved plates or discs 40 and 42 . The first of left operator or actuator 44 is preferably hydraulic but may be electric or pneumatic.
The second or right planetary gear assembly 50 also includes a second or right ring gear 56 which is connected to the input side of the second friction brake assembly 58 having a plurality of input friction plates or discs 60 . Interleaved with the plurality of input plates or discs 60 and connected to ground or the housing 18 are a plurality of stationary or ground plates or discs 62 . A second or right operator or actuator 64 is disposed in proximate, operable relationship to the interleaved plates or discs 60 and 62 . The second or right operator or actuator 64 is also preferably hydraulic but may be electric or pneumatic.
Alternatively, certain connections to the first planetary gear assembly 30 and the second planetary gear assembly 50 may be reversed, with first or left output half shaft or axle 14 connected to the first or left ring gear 36 , the first or left friction brake assembly 38 connected to the first or left sun gear 32 , the second or right output half shaft or axle 16 connected to the second or right ring gear 56 and the second friction brake assembly 58 connected to the second or right sun gear 52 .
Disposed within the common planet gear carrier 34 , 54 are a first plurality, typically three, of left planet gears 46 which are rotatably disposed on a like plurality of stub shafts 48 . If desired, needle or roller bearing assemblies (not illustrated) may be located between the planet gears 46 and the stub shafts 48 to reduce friction and spin losses. The first plurality of left planet gears 46 are in constant mesh with the first or left sun gear 32 and the first or left ring gear 36 . The first plurality of left planet gears 46 are elongated as best illustrated in FIG. 3 and are also on constant mesh with a respective one of a second plurality of right planet gears 66 which are also elongated and rotatably disposed on stub shafts 68 in the common carrier 34 , 54 . Again. If desired, needle or roller bearings (not illustrated) may be located between the planet gears 66 and the stub shafts 68 . In addition to meshing with the first plurality of left planet gears 46 , the second plurality of right planet gears 66 are in constant mesh with the second or right sun gear 52 and the second or right ring gear 56 .
It should be appreciated and understood that the various corresponding components of the first or left planetary gear assembly 30 and the second or right planetary gear assembly 50 , that is the sun gears 32 and 52 , the planet gears 46 and 66 and the ring gears 36 and 56 are the identical size and include the same size, pitch and number of teeth such that an even and equal torque split and delivery to the left and right axles or half shafts 14 and 16 occurs when the left and right friction brake assemblies 38 and 58 are fully released.
Several associated components cooperate with the torque vectoring differential 10 and are illustrated in FIG. 2 . Disposed in sensing relationship with the first or left output half shaft or axle 14 is a first or left speed sensor assembly 72 and similarly disposed with the second or right output half shaft or axle 16 is a second or right speed sensor assembly 74 . The speed of the input shaft 12 will generally be provided by an output speed sensor in the vehicle transmission (not illustrated) but, if desired, a dedicated input speed sensor assembly 76 may be disposed in sensing relationship with the input shaft 12 . Preferably, the speed sensor assemblies 72 , 74 and 76 are Hall effect sensors although other sensor types such as optical or variable reluctance sensors may be utilized. The outputs of the speed sensor assemblies 72 , 74 and 76 are provided to a control module 80 such as a chassis control module (CCM) or similar device. The control module 80 typically includes, for example, input devices, one or more microprocessors, storage, look up tables and output devices that control the first or left brake operator or actuator 44 , the second or right brake operator or actuator 64 and a limited slip clutch operator 96 as described directly below.
The torque vectoring differential 10 also optionally includes a controlled or modulating limited slip clutch 90 . The limited slip clutch 90 includes a first plurality of friction plates or discs 92 that are connected to the first or left ring gear 36 of the first or left planetary gear assembly 30 and a second plurality of friction plates or discs 94 are interleaved with the first plurality of plates or discs 92 and connected to the first or left sun gear 32 of the first or left planetary gear assembly 30 (and/or the first or left output shaft 14 ). The limited slip clutch 90 also includes a third hydraulic, electric or pneumatic operator or actuator 96 which is preferably under the control of the control module 80 .
Briefly, in operation, the brake assemblies 38 and 58 of the torque vectoring differential 10 may be partially or fully engaged to partially or fully inhibit differentiation by the pair of planetary gear assemblies 30 and 50 and direct more or less torque to one or the other of the axles or half shafts 14 and 16 . The limited slip clutch 90 may be partially of fully engaged to partially or fully inhibit differentiation by the pair of planetary gear assemblies 30 and 50 .
The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | A torque vectoring differential includes a pair of planetary gear assemblies having a common planet gear carrier which is driven from the output of a transmission. Each of the planetary gear assemblies include a ring gear that may be individually and selectively grounded (braked) to a stationary housing by a friction brake and a sun gear that is coupled through an axle to a respective drive wheel. Selective activation of the brakes controls the distribution, i.e., vectoring, of torque to each of the drive wheels. Each planetary gear assembly includes elongated planet gears which mesh not only with their respective sun and ring gears but also with the planet gears of the other planetary gear assembly. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to improvements in a lens antenna which comprises a dielectric lens attached to an aperture of a horn, and more specifically to a lens antenna which includes an improved dielectric lens for effectively lowering disturbances caused by electromagnetic waves internally reflected in the lens.
2. Description of the Related Art
As is known in the art, a lens antenna is comprised of a dielectric lens secured at an aperture (mouth) of a horn. The dielectric lens functions as a wave collimating element. A lens antenna is typically used in line-of-sight terrestrial microwave communications systems.
Before turning to the present invention it is deemed preferable to describe a known lens antenna with reference to FIG. 1.
FIG. 1 is a side view, partly sectional, of a known lens antenna, generally denoted by numeral 10, which comprises a plano-convex dielectric lens 12 and a conical horn 14 serving as a flared-out waveguide. The plano-convex lens 12 is made of a dielectric material such as polyethylene, polystyrene, etc. with a relative permittivity ranging about from 2 to 4. The lens 12 has plane surface 16 facing a free space and a hyperboloid of revolution (denoted by numeral 18) at the inner side. The horn 14 has a circular aperture to which the lens 12 is secured at its periphery. The horn 14 has an inner well covered with an electrically conductive layer, and has a flange 20 to which a corresponding flange 22 of a waveguide member 24 is attached. Reference numeral 26 denotes a wave guide.
As is well known in the art, the lens 14 transforms the spherical wave front of the wave radiated from a source 28 (i.e., primary antenna) into a plane wave front. To be more explicit, the field (viz., electromagnetic field) over the plans surface (viz., plans wave front) can be made everywhere in phase by shaping the lens so that all paths from the wave source 28 to the lens plane are of equal electrical length (Fermat's principle).
As shown in FIG. 1, part of a given incident wave 28 is reflected at two points of the lens 12: at the convex surface 18 (the reflected component is indicated by a broken line arrow 29) and at the plane surface 18. The reflection from the convex surface 18 does not return to the source 28 except from points at or near an axis 32 and thus are of no consequence. However, the energy reflected from the lens plans 16 returns back exactly along the radiation line 30 and may adversely affect the energy to be radiated from the wave source 26.
It is therefore highly desirable to reduce the above mentioned undesirable influence caused by the reflections from the plane lens surface.
SUMMARY OF THE INVENTION
It is therefore an object of the present to provide a lens antenna which has an improved dielectric lens for reducing disturbances caused by internally reflected waves.
One aspect of the present invention resides in a lens antenna comprising: a conical horn; and a lens attached to an aperture of said horn, said lens having a plane surface at a first side which faces a free space and a hyperboloid of revolution at a second side opposite the first side and being made of a dielectric material with relative permittivity ranging from 2 to 4, said lens being a circular lens with a diameter r, wherein said lens is provided with a cylindrical portion protruding from the plane surface of said tons, said cylindrical portion having a diameter of about r/3 and a height of about 0.17 λ 0 where λ 0 is a wavelength of a center frequency of a frequency range used with said lens antenna, said cylindrical portion being concentric with said lens.
Another aspect of the present invention resides in a lens antenna comprising: a conical horn; and a lens attached to an aperture of said horn, said lens having a plane surface at a first side which faces a free space and a hyperboloid of revolution at a second side opposite the first side and being made of a dielectric material with relative permittivity ranging from 2 to 4, said lens being a circular lens with a diameter r, wherein said lens is provided with a cylindrical portion recessed from the plane surface of said lens, said cylindrical portion having a diameter of about r/3 and a height of about 0.17 λ 0 where λ 0 is a wavelength of a center frequency of a frequency range used with said lens antenna, said cylindrical portion being concentric with said lens.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will become more clearly appreciated from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a side view, partly sectional, of a lens antenna referred to in the opening paragraphs of the instant disclosure;
FIG. 2 is a perspective view of a lens antenna according to a first embodiment of the present invention;
FIG. 3 is a side view, partly sectional, of the lens antenna of FIG. 2;
FIG. 4 is a vector diagram for use in describing the operations of the first embodiment;
FIG. 5 is a graph showing a radiation pattern of the lens antenna according to the first embodiment;
FIG. 6 is a graph showing reflection losses in the first embodiment;
FIG. 7 is a graph showing reflection losses in the prior art; and
FIG. 8 is a perspective view of a lens antenna according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the present invention will be described with reference to FIGS. 2 to 6.
FIG. 2 is a perspective view of a lens antenna 40 according to the first embodiment. The lens antenna 40 comprises a circular plano-convex dielectric lens 42 which is supported at the aperture of a conical horn 14', as in the prior art shown in FIG. 1. The lens 42 is made of a suitable dielectric material with relative permittivity ranging from 2 to 4. As shown, the lens 42 has a center portion which protrudes outwardly by a distance h. The protruded portion is substantially disk-shaped and thus hereinafter may be referred to as a disk or cylindrical portion 44. This disk portion 44 is formed on the lens 42 in a manner to be concentric therewith. It is to be noted that the disk portion 44 is part of the lens 42 and thus shaped when fabricating the lens 42. For the convenience of description, the plans surface of the disk portion 44 is denoted by numeral 44a, while the plane surface of the lens 42 except for the plane surface 44a is donoted by 42a. As in the prior art of FIG. 1, the lens 42 has a hyperboloid of revolution 18' at the inner side (see FIG. 3). The remaining portions of the lens antenna 40 are exactly the same as the counterparts of FIG. 1 and accordingly, the descriptions thereof will be omitted.
Designating the diameters of the lens 42 and the disk portion 44 as D1 and D2, respectively, it is preferable that the diameter D2 is set to about one third of D1 (viz., (D1)/3). This relationship of dimensions of D1 and D2 is determined as follows. It in known that the electromagnetic field near the edge of the lens 42 is less than that at and near the center thereof. That is, the amount of waves reflected from near the edge of the lens 42 differs from that at and near the center thereof. In order to effectively reduce the undesirable phenomenon caused by the reflected waves, it is highly desirable to equalize the amounts of waves reflected from the surfaces 42a and 44a. In view of this, it is preferable that the diameter D2 is determined so as to equal about one third of D1 (viz., (D1)/3).
In FIG. 3, two waves 50 and 52, which originate from the wave source 26, are shown. The waves 50 and 52 are respectively directed such as to pass through the surfaces 42a and 44a. As mentioned above, the energy of each of the waves passing through the lens plane (such as 42a and 44a) is partly reflected from the plane boundary. In FIG. 3, notations 50r and 52r represent respectively the reflected waves of the waves 50 and 52. It is understood that the reflected wave 52r is retarded by the electrical path length of "2×h" compared to the reflected wave 50r. According to the study conducted by the inventors, it was found that the height "h" was preferably about 0.17 λ 0 (λ 0 is a wave length of a center frequency of a designed frequency range). This mean that the reflected wave 52r is retarded by 2×0.17 λ 0 =0.34 λ 0 expressed in free space (air or vacuum) compared to the reflected wave 50r.
Further, the inventors conducted a computer simulation under the following conditions. That is to say, the lens 42 was made of polycarbonate with relative permittivity (ε r ) of 2.85, while the diameters D1 and D2 were 200 mm and 60 mm, respectively. It is assumed that the available frequency band ranged from 37.00 GHz to 39.50 GHz and accordingly, the center frequency was 38.25 GHz (λ 0 =7.84 mm) Therefore, the height "h" of the disk portion 44 was calculated using the following equation:
h=0.17λ.sub.0 /ε.sub.r.sup.1/2 ≈(0.17×7.84)/2.85.sup.1/2 ≈0.8 mm
As mentioned above, the wave reflected from the plane surface 44a (such as 52r) is delayed 0.34 λ 0 (expressed in free space (air or vacuum)) as compared to the wave reflected at the plane surface 42a (such as 50r).
One particular example showing the advantage of the first embodiment over the prior art will be discussed. First, the case where the above mentioned disk portion 44 is not provided is given (as in the prior art shown in FIG. 1).
Defining the parameters associated with the lens plane 16 as follows:
E 1i : wave incident on the lens plane 16;
E 1t : wave passing through the plane 16;
E 1r : wave reflected from the plane 16; and
R 1 : reflection coefficient (vector) at the plane 16.
Further, assuming:
|R.sub.1 |=|E.sub.1r /E.sub.1i |=0.3(1)
Since the reflection loss RL is given by 10 log|R| 2 , then
RL=10 log |R|.sup.2 =20 log |R|=20 log 0.3=-10.5 (dB) (2)
On the other hand, in connection with the first embodiment, the parameters associated with the plane 44a of the disk portion 44 are defined as follows:
E 2l : the wave incident on the lens plans 44a;
E 2t : wave passing through the plane 44a;
E 2r : the wave reflected from the plane 44a; and
R 2 : refection coefficient (vector) at the plane 44a.
Further, the parameters associated with the plane 42a of the lens 42 are defined as follows;
E 3l : wave incident an the lens plans 42a;
E 3t : wave passing through the plane 42a:
E 3r : wave reflected from the plane 42a; and
R 3 : reflection coefficient (vector) at the plane 44a
Rt=R 2 +R 3
Since E 2l =E 3l and |E 24 |=E 3r |, then
Rt=R.sub.2 +R.sub.3 ={|E.sub.2l |.sup.2 /(|E.sub.2l |.sup.2 +|E.sub.3l |.sup.2)}.sup.2 ×(E.sub.2r /E.sub.2l)+{|E.sub.3l
|.sup.2 /(|E.sub.2l |.sup.2 +|E.sub.3l |.sup.2)}.sup.2 ×(E.sub.3r /E.sub.3l)=(1/√ 2·E.sub.2i)×(E.sub.2r +E.sub.3r) (3)
Therefore, the phase difference (denoted by θ) between E 24 and E 3r is given by
θ=0.17×2×2π=0.68π
In the above, it is assumed that the wave amounts reflected at the planes 40a and 42a are equal each other.
FIG. 4 is a vector diagram showing the relationship of E 2r and E 3r whose phase difference is θ.
Assuming |E 2r /E 2l |=0.3, then we obtain
Rt=1/√ 2×0.3{(1+cos θ).sup.2 +sin.sup.2 θ}=1/√ 2×0.3×0.964=0.204 (4)
As a result, the reflection loss (denoted by RL') in the above case is as follows.
RL'=10 log |Rt|=-13.8 dB (5)
It is understood, from the above computation, that the reflection loss can be reduced by 3.3 dB as compared to the prior art.
The inventors conducted a computer simulation to determine a wave radiation pattern when a vertically polarized wave is applied from the waveguide 28. FIG. 5 is a graph showing the result of the computer simulation, which clearly indicates that a good radiation pattern can be obtained even if the disk portion 44 is formed.
Further, the inventors investigated reflection losses occurring in the first embodiment (the result is shown in FIG. 6) and in the prior art (the result is show in FIG. 7), both over the frequencies ranging from 35 GHz to 40 GHz. This frequency range includes the frequency band (37.0 GHz to 39.5 GHz) over which the lens antenna embodying the present invention is preferably utilized. In this investigation, a reference level (0 dB) was determined when the waves radiated from the waveguide 28 were totally reflected at the plane surfaces of the lens 12 (FIG. 1) and 42 (FIG. 3). As shown in FIG. 6, the worst reflection loss in the first embodiment was about -16.4 dB. In contrast to this, the worst reflection loss in the prior art was about -11.0 dB as plotted in FIG. 7. That is, this examination indicates that the first embodiment was able to reduce the reflection loss by about 5.4 dB compared to the prior art.
FIG. 8 is a diagram showing a second embodiment of the present invention. As shown, a lens antenna 40' includes a dielectric lens 42' which has a cylindrical recess 44' with the depth h. Other than this, the second embodiment of FIG. 8 is identical to the first embodiment with respect to structure. With the second embodiment, each wave reflected from the inner surface of the recess 44' becomes shorter by 0.34-wavelength (2 h=0.34) than that reflected from the inner surface other than the recess 44'. It is understood that the operations as discussed above with respect to the first embodiment is applicable to those of the second embodiment.
It will be understood that the above disclosure is representative of only two possible embodiments of the present invention and that the concept on which the invention is based is not specifically limited thereto. | A lens antenna is disclosed which comprises a conical horn and a lens attached to an aperture of the horn. The lens has a first planar surface at a first side which faces free space and a hyperboloid of revolution at a second side opposite the first side and is made of a dielectric material with relative permittivity ranging from 2 to 4. The lens is provided with a cylindrical portion which has a second planar surface parallel to the first planar surface and displaced from the first planar surface by a predetermined distance. The cylindrical portion being concentric with the lens. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to a centrifugal pump, in particular for blood in cardiac substitution or assist devices, as generically defined by the preamble to claim 1 . In particular, the invention relates to an electrically driven rotary pump of the radial/centrifugal type for permanent implantation in patients with terminal cardiac insufficiency who require mechanical support of their blood circulation.
Blood pumps, especially blood pumps or pumps for other vulnerable fluids, must meet special requirements:
1. High hydraulic efficiency, to keep the heat loss given up to the blood or fluid slight and to keep the energy storing means small.
2. Entirely contactless rotation of the rotor inside a hermetically sealed pump housing, thus precluding any wear, abrasion, and local heat development from mechanical friction.
3. Avoidance of standing eddies and flow stasis zones as well as minimal dwell times of the blood or fluid in the pump, to avoid damage to the fluid and the activation of blood coagulation.
4. In blood pumps, minimizing the cell-damaging shear stresses to which the blood is exposed on passing through the pump.
5. Security against mistakes by eliminating complex sensor-based positional regulations of the rotor while simultaneously reducing energy consumption.
6. Eliminating a drive motor with a supported shaft that is subject to wear.
Blood pumps of conventional design, in which the drive of the rotor is done by an electric motor with a supported shaft that penetrates the pump housing and is provided with a shaft seal are therefore unsuited for permanent implantation. Hermetically sealed housings, through whose wall the pump rotor is set into rotation by means of a magnetic coupling, do eliminate leaks but still require an external electric motor. Furthermore, the pump rotor in the housing must be guided by end journal bearings that are bathed with blood; these bearings wear and from local heating denature blood proteins and are capable of activating the coagulation system, which can lead to emboli from abrasion and clots.
A completely contact-free rotation of the pump rotor in the blood can be achieved by means of passive and active magnet bearings, hydrodynamic slide bearings, or a combination of these principles.
Any possible use of this principle must take Earnshaw's theorem into account, which states that it is not possible to keep a body floating in space in a stable position by means of constant magnetic, electrical, or gravitational fields. Any apparent position of equilibrium is in fact unstable, since the body is in that case at a maximum of potential energy. In at least one axis in space, a stabilizing force acting on the system is therefore required. This force must be all the greater, the farther the body is located from the site of the maximum energy. Conversely, only slight restoring forces are necessary, if the system is located a priori in the vicinity of the unstable equilibrium.
Magnetically supported pump rotors with open blades are described in U.S. Pat. No. 6,227,817. Here, a combination of passive magnet bearings for radial stabilization and sensor-based active axial electromagnetic suspension is described. Besides the complex production, this embodiment requires an elongated gap between the rotor and the housing with only inadequate purging and high energy consumption for the axial stabilization, which must counteract the considerable hydraulic axial shear that is generated by an open impeller.
Blood pumps with complete magnetic suspension are described in European Patent Disclosures EP 0 819 330 B1 and EP 0 860 046 B1. Here, the rotor of the pump is embodied as a rotor of a permanent-magnetically excited electrical synchronous machine. The torque is generated by a revolving, radially engaging electromagnetic stator field, as is the position control of the rotor in the radial direction. Separate control windings of the stator are used for this purpose, which convert the signals of spacing sensors into centering forces by way of electronic closed-loop control circuits. Because of the externally located stators for the drive and positional regulation, this pump requires a relatively large amount of installation space. The stabilization of the other three spatial degrees of freedom that cannot be actively triggered is done by passively acting magnetic reluctance forces. Problems also arise in versions with open impellers because of the high hydrodynamic axial shear, which unavoidably occurs. To overcome them, additional active or passive magnet bearings as well as hydrodynamic aids in the form of nozzles, impact plates, inflow tubes, flow resistors, and sealing gaps are proposed, all of which increase the complexity of the system, lessen its efficiency, create flow stasis zones, induce high shear stresses, and are thus entirely unsuitable for the realization of a blood pump, especially for permanent implantation.
Bearingless blood pumps with magnetic suspension and open impellers are also disclosed in U.S. Pat. No. 6,071,093. However, the transmission of the torque is done here by an axially engaging encircling electromagnetic stator field. The axial rotor position and the tilting of the rotor in the housing are stabilized by a sensor-based electromagnetic feedback by means of actuators, while at the same time passive permanent magnet bearings provide the radial centering. The problems of the axial instability of an open impeller are solved—besides by electromagnetic feedback by means of sensors and actuators—by a fluidically effected compensation. This compensation is based on the action of a throttle gap, located on the outer circumference of the rotor, which as a function of the axial rotor position either limits or enables the back flow on the side of the rotor facing away from the blades. In this version as well, there is the risk of high shear stresses and the generation of flow stasis zones on the back side of the rotor.
U.S. Pat. No. 5,947,703 also describes an electromagnetically suspended centrifugal pump. Here, the drive of a covered impeller is effected by means of a unilaterally axially engaging permanent-magnet face-end rotary coupling or by an encircling stator field, whose forces of attraction cause the pump rotor at the housing to strike the wall unless the axial rotor position is regulated by a sensor-based active electromagnetic feedback. If this regulation fails, mechanical emergency bearings in the form of end journal bearings, slide bearings, point bearings, and hydrodynamic pressure bearings are provided, which are meant to prevent a life-threatening seizing of the pump rotor. All these proposals share the disadvantage of mechanical wall contact between the rotor and the housing, with the known consequences of damage to the blood.
International Patent Disclosure WO 01/42653 A1 describes a centrifugal pump with electromagnetic active position regulation of the pump rotor in all six degrees of freedom in space; the position, speed and acceleration of the rotor are not detected by sensors but derived from current signals of the active magnet bearings. This disadvantageously makes for an extremely complex mechanical construction of the rotor and multiple stators as well as extremely complex regulating electronics with an additional energy requirement, especially since to avoid high axial destabilizing forces, an ironless motor has to be used, which because of its poor efficiency heats up sharply.
The aforementioned disadvantages of active electromagnet bearing of the pump rotor were the impetus for a number of inventions in which complicated sensors and electronics were meant to be eliminated by means of hydrodynamic stabilization of the rotor/impeller.
For instance, in U.S. Pat. No. 5,324,177 and International Patent Disclosure WO 01/72351 A2, a hydrodynamic support bearing are used for radial stabilization of the rotor of an electrical direct current machine, and it carries the open pump rotor. A disadvantage here is the long axial length of the narrow, eccentric bearing gap, in which high shear stresses are operative, and which for being washed out requires auxiliary blades and a purging circuit from the high- to the low-pressure side of the pump. This arrangement involves the familiar risks of high shear and inadequate heat dissipation, which lead to traumatization of the blood.
These disadvantages are partly avoided in U.S. Pat. No. 6,227,797. In it, in a rotationally symmetrical housing, the pump rotor is embodied such that its surfaces on all sides form wedge-shaped gaps relative to the housing, in the direction of the active faces inclined in the direction of the relative motion. The pump rotor and housing thus form a hydrodynamic three-dimensional slide bearing, as is entirely usual in mechanical engineering. The supporting fluid film of blood, which acts as a lubricant for these wedge-shaped faces, covers a large area and especially at the circumference of the rotor is subjected to high shear stress, for which typical values of 220 N/m 2 are given. This shear stress is thus within a range in which damage to blood cells, especially thrombocytes, from shear must be feared. Other disadvantages of this version are that the open pump rotor is surrounded on all sides relative to the housing by narrow gaps, in which high viscous friction prevails. The necessity of splitting the rotor into segmental blocks, to allow the blood to pass from the inlet to the outlet of the pump, stands in the way of optimizing the fluid-mechanical efficiency of the pump. Accordingly, for an implantable blood pump with low energy consumption, which is a worthwhile goal, the stated hydraulic degrees of efficiency of at most 11% are prohibitively low. The long axial length of the rotor moreover causes hydrodynamic radial shear on the rotor, which can necessitate a split spiral conduit, which favors the development of thromboses. Moreover, the housing is complicated to manufacture. The embodiment of a covered pump rotor shown in FIG. 20 , with a surface structured in wedgelike shape in sectors, does not overcome these disadvantages, especially since it cannot be seen what path the blood is supposed to take to flow through such a rotor.
A quite similar version of hydrodynamic axial stabilization of an open pump rotor by means of floating wedge-shaped faces inclined in the direction of rotation is described in International Patent Disclosure WO 00/32256. Once again, the disadvantages are damage to the blood and a complicated housing construction. The radial centering of the rotor is moreover done here not by hydrodynamic but rather by permanent magnet reluctance forces of a face-end rotary coupling or of an electromagnetic drive motor.
WO 99/01663 discloses a hydraulically suspended pump rotor, which is meant to float by Archimedes buoyancy, since it has the same density as the fluid to be pumped. This pump must be embodied with two inlets, or the inflow must be diverted inside the pump by 180°; the result is large wetted internal surfaces as well as questionable hydrodynamic stability.
WO 01/70300, for hydrodynamic stabilization, proposes a conical rotor with slitlike openings for the flow to pass through and guide faces, through which a fluid flow oriented counter to the housing is generated that is meant to have a stabilizing effect. If that does not suffice, an active magnet bearing is provided for radial stabilization, but this represents additional electronic complication and expense. In a number of patents (WO 00/32257, WO 00/64508, EP 1 027 898 A1, and U.S. Pat. No. 5,840,070), combinations of the most various principles are employed for stabilizing the pump rotor: ball-spur bearings, passive permanent magnet radial bearings, active-sensor-based electromagnetic axial bearings, hydrodynamic wedge-shaped face bearings with both an axial and a radial action, supplemented by such auxiliary constructs as profiling of the rotor and/or of the housing by means of overlays, ribs, and disks, conduits, and other provisions.
It is notable that at least three of these principles must always be employed in combination in order to assure contactless rotation of the impeller in the pump, and that in the wedge-shaped face bearings, given the stated gap width of approximately 0.013 to 0.038 mm, shear stresses (of over 600 N/m 2 ) occur, which are highly likely to damage blood.
A critical assessment of the prior art discussed consequently shows that the contactless rotation of the rotor of a centrifugal pump in the housing is attained either by means of high complexity and expense for sensors and electromagnetic regulation, or at the cost of a high hydrodynamic load on the blood from damaging shear stresses.
BRIEF SUMMARY OF THE INVENTION
The object of the present invention is to create a centrifugal pump with a bearingless rotor, in which in a simple way that protects fluid, the rotor can be stabilized in the axial and radial directions and has high efficiency.
This object is attained with a centrifugal pump having the characteristics of claim 1 . The dependent claims recite advantageous refinements.
The axial stabilization of the pump rotor is done hydrodynamically by means of the fluid pumped through the rotor. To that end, the radially inward-oriented fluid flow between the rotor surfaces and the housing, which occurs because of the prevailing pressure difference between the radially outer and the radially inner regions of the pump housing, can generate the hydrodynamic forces for axial stabilization of the rotor. The rotor is embodied symmetrically to its center plane and has an upper and a lower covering. As a result, defined flow conditions result for the lost fluid flow oriented inward from the periphery, which flow can be used to axially stabilize the rotor.
According to the invention, the flow-dictated pressure drop in the side chamber of the axially symmetrical pump rotor, covered on both ends, is accordingly utilized: The outlet pressure generated by the pump at the rotor circumference is reduced to the inlet pressure toward the center by way of the back flow through the rotor side chambers. Because the rotor and/or the pump housing are shaped such that the axial spacings between the upper and lower coverings of the rotor and the upper and lower housing walls are less in the radially inner region than in the radially outer region of the rotor, a throttling action arises in the central region of the coverings when the fluid flows from the outside inward. The throttle gap causes the great majority of the pressure loss, and as a result a higher pressure continues to be preserved in the peripheral region of the coverings, and hence a force component is exerted on the entire covering that acts counter to narrowing the gap. This force is greater, the narrower the gap in the central region of the covering.
Thus if the rotor moves upward, the upper gap narrows. The resultant increase in the pressure of the fluid then presses the rotor downward again. Conversely, the fluid presses the rotor upward again if the rotor should move downward from the middle. Hence a hydrodynamic stabilization of the axial position of the pump rotor occurs automatically. Upon axial deflection of the rotor, the throttle gap is narrowed in the direction of the deflection and widened on the opposite side. On the side of whichever gap is wider, this causes a relative increase in the radially inward-oriented back flow and hence an asymmetrical hydrodynamic pressure drop. The rotor side chambers form parallel-connected nozzles, whose differential pressure is operative on the entire surface of both closed coverings of the rotor, and an axially stabilizing restoring force acting symmetrically to the position of repose of the rotor is thus generated. The rotor is therefore stabilized against deflection in the z axis.
The same is true for the tilting of the rotor, or in other words a rotary motion about the x and y axes. In that case as well, the axially symmetrical throttle gaps are narrowed and widened contrary to one another, with the consequence of a restoring force in the direction of a stable rotor position in the housing. Until now, these effects have not been utilized in bearingless pumps. An essential precondition for the desirable minimizing of the stabilizing energy required is the axial symmetry, according to the invention, of the pump rotor and the rotor side chambers.
The spacings between the upper and lower rotor coverings and the upper and lower sides of the housing can decrease continuously, for instance. Preferably, however, annular constrictions can also be embodied in the radially inner region of the rotor and housing, between the rotor coverings and the upper and lower housing walls, and these constrictions bring about the increased pressure drop in the fluid and the desired increase in pressure. The farther inward the constriction is located, the more engagement area is available for the fluid to stabilize the axial position of the pump rotor.
The radial stabilization of the rotor can be done purely passively on the basis of reluctance forces. The hydrodynamic radial shear, which urges the rotor out of the center of the rotary motion, should be minimized. To that end, the projection area of the rotor in the x-y/z plane is preferably kept minimal as an active face of radially destabilizing pressure forces. It is determined solely by the thickness of the coverings of the rotor. The rotor may preferably be made entirely of paramagnetic and/or ferromagnetic material and permanently magnetized. In that case, no encapsulation of discrete permanent magnets is necessary, which contributes to increasing the radial projection area. A further provision against radial instability is to provide a circular, rotationally symmetrical annular gap, which divides the rotor side chambers from a spiral conduit that carries the pumped flow tangentially away. As a result, a constant flow resistance to the fluid that emerges from the rotor is generated, and hence a radial pressure force on the rotor that acts uniformly via the circumference of the rotor is generated. The third provision against radial instability comprises a suitable design of the spiral conduit that carries the flow away, in which radially destabilizing pressure forces in the region of the tongue are avoided.
The drive of the pump is preferably done in the form of a permanently excited electrical synchronous machine, whose rotor is formed by the rotor of the pump, which is located between two symmetrical stators with a wide air gap. The stators may be rotated counter to one another, as can the permanent magnet regions of the rotor that are split into two planes. The pole coverings and the topology of the electromagnetic flux linkage can be optimized so that with the least mass of magnetic material, high efficiency and low waviness is attained, that is, high constancy of the torque and low axial rigidity of the magnet system, thereby making the hydrodynamic suspension of the rotor possible. Simultaneously, the magnetic reluctance forces between the stators and the rotor are utilized for centering the rotor radially.
The centrifugal pump of the invention is especially suitable for use as a blood pump and in that form for implantation in the human body, since it requires only little space and is absolutely maintenance-free. The pump can be used as a blood pump for assisting the cardiac activity of a patient or in conjunction with a heart-lung machine. The pump can also be used to pump other fluids, particularly aggressive and dangerous fluids or vulnerable fluids, in which contact with the outside is to be avoided. The components of the pump that come into contact with the fluid can be provided with a coating adapted to the particular fluid.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Preferred exemplary embodiments of the centrifugal pumps of the invention are described below, particularly for use as permanently implantable blood pumps for cardiac assistance, in further detail and in terms of their function in conjunction with drawings.
Shown are:
FIG. 1 , a cross section through an exemplary embodiment of a centrifugal pump of the invention;
FIG. 2 a , a perspective view of the rotor of the pump of FIG. 1 with the upper covering partly removed;
FIG. 2 b , a schematic cross section through the rotor and housing of the pump of FIG. 1 for illustrating the geometric parameters;
FIG. 3 a , 3 b , a schematic illustration of the flow conditions through the rotor of a centrifugal pump with a constant width and a radially inwardly decreasing width, respectively, of the rotor side chamber;
FIG. 4 , graphs showing the radial course of the pressures in the rotor side chambers;
a) for an axially middle position of the rotor in the housing;
b) with axial offset of the rotor toward the inlet of the housing;
FIG. 5 , a graph showing the course of the restoring force as a function of the axial deflection from the middle rotor position for throttle gaps of different widths;
FIG. 6 , graphs showing the radial course of the pressures in the rotor side chambers in the event of tilting of the rotor in the housing;
FIGS. 7 a, b, c , cross sections through various embodiments of the throttle gap in centrifugal pumps of the invention;
FIG. 8 , throttle curves of the pump of the invention for different rotary speeds;
FIG. 9 , graphs showing the hydraulic efficiencies over the flow rate of the pump of FIG. 1 at different rotary speeds.
DETAILED DESCRIPTION OF THE INVENTION
The centrifugal pump 10 of FIG. 1 has a pump housing 11 with an inlet 12 and a tangential outlet 13 for blood or some other fluid. Otherwise, the pump housing 11 is closed in a fluid- and gas-tight manner. A pump rotor 14 is located in bearingless and rotatable fashion in the interior of the pump housing 11 . With the aid of the pump rotor 14 , the blood flowing in through the opening 12 is pumped radially outward and toward the outlet 13 . To that, the pump rotor has feeder blades 15 . The feeder blades 15 are covered at the top and bottom by an upper covering 16 and a lower covering 17 .
The pump rotor 14 , at least in its circumferential region, has permanently magnetized regions. In the example shown, however, it is made entirely of a paramagnetic and/or ferromagnetic material. Thus at the same time it forms the rotor for a drive motor, which besides the rotor 14 has two annular stators 18 , 19 , which have many uniformly distributed portions 20 , 21 , protruding in the direction of the rotor 14 , that are each surrounded in a preferred embodiment by a respective winding 22 , 23 . However, winding arrangements are also conceivable in which a plurality of the axially protruding portions 20 , 21 are enclosed=“surrounded”] by a winding 22 , 23 . The two stators 18 , 19 are located outside the housing, so that the drive of the pump rotor 14 is effected in contactless fashion. As a result, only minimal loads occur for the blood to be pumped in the housing 11 . The rotor 14 and the housing 11 are preferably coated, where they come into contact with blood, with a blood-compatible material.
The stators 18 , 19 generate a rotating magnetic flux in the space between the regions 20 , 21 and the rotor 14 . Simultaneously, the two stators assure radial centering of the rotor 14 in the housing 11 . The radial centering is effected purely passively, based on reluctance forces.
Below, the way in which in the pump 10 the stabilization of the pump rotor 14 against displacement in the housing 11 in the axial direction is accomplished by hydrodynamically generated pressure forces will be described.
The rotor 14 has coverings 16 , 17 , which are entirely axially symmetrical and smooth and which enclose blades 15 , whose number and shape can be optimized to suit flow-dynamic requirements ( FIG. 2 a ). In the embodiments shown here, the number of blades is six. The blood enters on the intake side through an opening 126 into the rotor 14 . A second opening 127 of the same size in the lower covering serves to equalize pressure between the rotor side chambers 26 , 27 , so that regardless of the pressure and flow conditions prevailing there, the same pressure always prevails at the edges, oriented toward the center, of the openings 126 , 127 ( FIG. 1 ). The blood leaves the rotor 14 after passing through the blade conduits at the outer circumference into the annular gap 124 leading away and finally into the spiral conduit 24 at high pressure.
The rotor side chambers 26 , 27 in FIG. 2 b are defined by the coverings 16 , 17 of the rotor 14 and the walls of the housing 11 . In a centrifugal pump with a covered pump rotor 14 , two flow directions prevail in these rotor side chambers 26 , 27 : The boundary layer, adhering directly to the rotating coverings 16 , 17 , is moved outward by centrifugal force, while the built-up pressure near the stationary housing 11 and in the predominant volume of the side chamber 26 , 27 generates a radially inward-oriented back flow 28 , which is known as a short-circuit flow or leakage flow and which lessens the hydraulic efficiency. In industrial pump construction, labyrinth seals near the axis, among other provisions, serve to reduce these losses. For blood pumps, their use is recommended because of the development of high shear stresses and flow stasis zones that are difficult to purge thoroughly.
The symbols used hereinafter to describe the geometry of the pump rotor and the housing are shown in FIG. 2 b . They stand for the following:
R Radius of the covering of the rotor;
r 1 Radius of the inflow openings into the rotor;
r 2 Radius at the inlet into the throttle gap;
r 3 Radius at the beginning of the permanent magnet regions of the coverings;
r 4 Inner radius of the housing;
r 5 Outer radius of the circular annular gap;
H Width of the rotor side chamber at the rotor circumference;
h Axial width of the throttle gap;
h 1 Blade height at the rotor inlet;
h 2 Blade height at the rotor circumference;
h 3 Height of the circular annular gap;
l Radial length of the throttle gap (r 2 -r 1 );
d Thickness of the coverings.
In the pumps according to the invention, the unavoidable energy loss of the radial back flow 28 in the rotor side chamber 26 , 27 is utilized for generating a hydrodynamic restoring force against axial migration of the rotor by means of a novel geometric design of this gap space 26 , 27 , as is shown in FIG. 3 .
In FIG. 3 a , a rotor side chamber is shown, with a constant axial width over the radius of the covering 16 ′, 17 ′. In the middle position of the rotor, equal flow intensities occur in both rotor side chambers, since the pressures are equal at the circumference and in the center of the rotor, and thus symmetrical pressure distributions act on the coverings. If the rotor in FIG. 3 deflects axially toward one side, the flow is speeded up in the narrower rotor side chamber, and consequently the pressure on the covering drops there, and the opposite occurs in the widened, diametrically opposite rotor side chamber with a delayed flow there, in obedience to Bernoulli's Law and in analogy with the familiar “hydrodynamic paradox”. The compensating motion is therefore reinforced until the rotor strikes the wall of the housing.
The geometric design according to the invention of the rotor side chambers 26 , 27 turns this effect around ( FIG. 3 b ): The gaps between the coverings 16 , 17 and the housing 11 , in their radially inner regions, each have—relative to the rest of the gap—a major axial narrowing over a short radial length, so that directly before the inlet opening of the rotor, there is one symmetrical throttle gap 116 , 117 ( FIG. 1 ) is embodied on each side. The leakage flow 28 here meets a high terminal serial resistance. In a middle position of the rotor, pressure equilibrium prevails in the upper and lower rotor side chambers. Upon axial deflection of the rotor, the proportion of the throttle gap in the gap that is becoming narrower compared to the total gap resistance becomes greater and greater. As a result, the pumping pressure at the rotor circumference in the narrowed rotor side chamber is approximately preserved radially inward to close to the throttle gap and only there is it sharply reduced via the terminal resistance of the throttle. In the diametrically opposed gap of increasing size, the influence of the throttle restriction becomes less and less. The pressure is reduced radially inward uniformly, beginning at the circumference, over the entirely length of the gap.
The resultant difference in the pressure forces on the closed coverings therefore generates a force, upon each axial deflection of the rotor from the middle position, that is proportional to the deviation and restores the rotor. It is understood that in the narrow, annular throttle gap 116 itself, which is axially plane-parallel to the housing, the aforementioned flow law still applies, and accordingly the accelerated flow in the narrower gap would destabilize the rotor in the direction of the narrowing. The effective area of the pressure forces, however, is only a small fraction here of the surface of the coverings, and hence the axially restoring forces greatly predominate.
Measurements of a rotor (R=20 mm) in a pump of FIG. 1 , for an axial offset of the rotor, have shown radial pressure courses in the rotor side chambers as shown in FIGS. 4 a and b . Each axial offset ( FIG. 4 b ) causes an asymmetry of the radial course of the pressure decrease in the rotor side chamber. The resultant pressure difference becomes operative, over the greatly predominant area of the coverings, as a restoring force that positions the rotor axially centrally.
The amounts of the restoring forces that result from the pressure differences of FIG. 4 are shown in FIG. 5 . What is wanted is as great a rigidity dF/dz as possible over the entire range of the deflection in the direction z ( FIG. 2 a ). It can be seen that a narrow throttle gap (h=0.2 mm) meets this requirement in linear fashion and more steeply than a wider gap (h=0.3 mm); in both cases, at maximal deflection, restoring forces of approximately ±5 N are attained, and this is done largely independently of the working pressure and pumping rate of the pump (120±20 mmHg, 5±2 l/min). For the geometry of the throttle gap, a ratio h/R in the range of from 0.016 to 0.008 and of I/R in the range of from 0.16 to 0.08 has proved especially favorable, as have corresponding heights of the throttle gap of from 0.32 mm to 0.16 mm and an axial length of from 1.6 to 3.2 mm, in the preferred embodiment having a radius R of the rotor of 20 mm. In the range of h/R<0.006, with increasing shear forces, the rigidity does not increase further. In the range of h/R>0.2, adequate restoring forces are not attained.
A rotational deflection of the rotor ( FIG. 6 ) about the axes (x, y), or in other words tilting in the housing, causes a contrary narrowing and widening of the throttle gaps symmetrically to the axis of rotation and hence different radial courses of the leakage flows and the pressure decrease in the diametrically opposed rotor side chambers. The resultant differential pressure becomes operative as a restoring pressure force on the entire area of both coverings and rotates the rotor back into its neutral position.
Given a typical geometry of the throttle gap of (h/R)=0.01 and a radial location of the inlet into the throttle gap of (r 2 /R)=0.35, a rotor of R=20 mm can tilt by an angle of 1.6°, when the throttle gap is radially closed and the rotor runs up at a tangent and at a point at the radius r 2 . The gap width H at the rotor circumference, in the preferred version, has been found favorable in the range of H/R=0.05±0.01 (H=0.8−1.2 mm). The selected geometry precludes the rotor's striking the wall in the ranges of higher circumferential speeds at the radius R, so that the inflow of the stabilizing back flow into the rotor side chamber is not hindered.
The design of the rotor side chambers and of the throttle gaps in accordance with the invention thus brings about a spatial stabilization of the rotor into its geometrically neutral, symmetrical position in the housing counter to translation in the direction ±z and rotation about the axes x and y.
Further possible versions of throttle gaps in pumps according to the invention are shown in FIG. 7 . In the pump of FIG. 1 , the rotor side chambers 26 , 27 taper steadily from the radius R to the inlet into the throttle gap 116 , 117 at the radius r 2 ; until the inlet into the rotor at the radius r 1 , the gap has a constant h, as FIG. 7 a shows. In FIG. 7 b , one possible variant is shown in which the throttle gap, while preserving the ratios h/R (see above), is formed by a bead 30 , which is shaped from the coverings 16 , 17 in the region of the radii r 2 to r 1 . In this way, the predominant portion of the rotor side chambers is kept wider, so that the viscous friction there between the rotating rotor and the stationary housing is reduced, and the stabilizing action of the gap is still preserved. In FIG. 7 c , a possible variant is shown in which the shape of the coverings with the embodied bead 132 corresponds to FIG. 7 b . Here in addition, a bead 133 located radially farther outward is shaped from the housing, and the gap height continues to maintain the ratios h/R according to the invention. In this version, besides the axially stabilizing action of the throttle, a radial force component is generated, which reinforces the centering of the rotor.
The restoring pressure forces become operative very quickly in the event of any positional deviation and hence change in the flow geometry whatever, namely with the propagation speed of the pressure change brought about in the incompressible fluid, or in other words the speed of sound. In blood (as in water), this speed is approximately 1500 m/s (in air, it is approximately 300 m/s). For the geometry shown for the preferred version, a delay in the effectiveness of a positional deviation of the rotor of approximately 50 microseconds is thus calculated.
Unsteady-state numerical simulation calculations, taking forces of acceleration and inertia into account, have shown that sudden changes in position of the rotor are completely compensated for within one to two revolutions. Upon a sinusoidal axial relative motion of the rotor with respect to the housing, a phase displacement between deflection and restoration of approximately 10 ms results, corresponding to approximately one-half a rotor revolution.
This kind of fast response by the position regulation is especially advantageous upon startup of the pump. When the pump is stopped, the rotor is in an incidental, axially displaced or tilted position in the rotor. The stabilizing pressure forces are not generated until during operation. A hydrodynamic suspension of the rotor within its first few revolutions prevents structural damage from friction to the rotor and housing.
The speed and rigidity of the position regulation, according to the invention, of the rotor is also advantageous whenever the person who has an implanted blood pump is exposed in everyday life to varying accelerations in different axes in space. The demonstrated compensation times of approximately 10 ms (100 Hz) with the rigidity of approximately 20 N/mm allow the expectation that the pump rotor will be reliably prevented from striking the housing even upon multiple ground acceleration.
Radial migration of the rotor, that is, translation in the direction ±x and ±y, is not hindered by the above-described axial positional stabilization by pressure forces on the covering. The radial stabilization of the rotor is done passively by reluctance forces. It is advantageous in this respect to keep the destabilizing radial shear, which occurs in every centrifugal pump, slight and to compensate for it. This is successfully done by several provisions:
The radial shear increases in proportion to the total height (h 2 +2d) of the rotor at the circumference. The rotor is therefore kept especially low in height, and ratios of (h 2 /R) in the range of from 0.08 to 0.12 and of (d/R) in the range of from 0.05 to 0.1 have proved favorable. An especially low-height design is made possible by the production, according to the invention, of the coverings from solid, biocompatibly coated magnetic material, as a result of which an encapsulation of discrete magnets can be dispensed with.
The radial shear (SR) increases exponentially, if the rotor is not operating at the best point (Q opt ) of its efficiency: SR˜1−(Q/Q opt ) 2 (Bohl, W., Strömungsmaschinen 2, 8th Ed., Vogel Fachbuchverlag, Würzburg (2002)). From FIG. 9 it can be seen that the optimal efficiencies, at the expected rotary speeds of 2400 to 3000 min −1 , of 5±2 l/min in the operating field of the pump are attained, as a result of which the radial shear is minimized further.
Carrying the volumetric flow away through a spiral conduit with a tangential outlet leads to radial shear whenever a sudden pressure change occurs in the working range in the region of the tongue (cutting edge). According to the invention, this is largely prevented by providing that the volume pumped by the rotor, before entering the spiral conduit, passes through a circular annular gap, whereupon a rectification of the flow ensues. The further outflow of the fluid accordingly takes place via the spiral conduit, which can be embodied as an Archimedes spiral of approximately circular cross section. An axial height h 3 of the annular gap of h 3 /h 2 in the range of from 0.6 to 2.0, a radial length (r 4 /r 5 ) in the range of from 0.8 to 1.0, and a circular cross section, increasing steadily over the circumference of the spiral conduit, with a diameter h 3 at the tongue and a terminal diameter at the tangential outflow of 4·h 3 have proved favorable in the context of the invention. With this preferred geometry, in the range of maximum efficiency, no radially destabilizing sudden pressure change occurs in the region of the tongue.
The three characteristics described for reducing radial shear can largely minimize it but not compensate for it. For that purpose, the aforementioned magnetic reluctance forces generated by the stator and rotor geometries are used.
The hydraulic efficiency of an implantable blood pump should be as high as possible, since any power loss caused by viscous friction, turbulence, and short-circuit flows contributes to blood damage and is finally transmitted to the blood as thermal energy. A further factor is that the power demands made of the electric drive mechanism and the energy expenditure required for that purpose decrease inversely proportionally, which is favorable to the miniaturization desired.
By means of the described geometry of the wheel side chambers and the conduits leading away, and in combination with a covered rotor with optimal blading, previously unknown efficiencies are attained. This is demonstrated in FIG. 8 and FIG. 9 in terms of measured throttle curves and associated efficiencies. In the typical operating range of the pump of the pump of 5±2 l/min flow rate, at pressures of 120±20 mmHg, the hydraulic pump powers (p·V) amount to 1.4±0.7 watts. The rotary speeds required for this are in the range from 2400 to 3000 min −1 .
When a test fluid with the viscosity of blood (4 mPas) is used, the pump of FIG. 1 has the efficiencies shown in FIG. 9 , which in the typical operating range amount to from 0.4 to 0.47. This is approximately equivalent to four times the values that have been given for known blood pumps.
The required shaft power of approximately 3±1.5 watts is correspondingly low, which is an especially favorable prerequisite for miniaturizing the drive and the power supply.
For the hydrodynamic stabilization according to the invention of the rotor, the efficiency-reducing back flows in the rotor side chamber are utilized. In the typical operating range these amount to approximately 2 to 3 l/min. To generate a net flow rate of 5 l/min, accordingly from 7 to 8 l/min must be demanded of the rotor. This is equivalent to a hydraulic additional power of 0.5 to 0.8 watts for stabilizing the rotor, and thus an additional need of only approximately 20% in terms of shaft power. However, that need not be additionally exerted, but instead originates in the wasted/dissipated energy of the leakage flows that has gone unused in other pumps.
The pump according to the invention is especially effective and is intended to pump the blood in as protective a way as possible. The most important prerequisite for this is the avoidance of high shear stresses. The blood pump is distinguished from known pumps with hydrodynamic slide bearings and others in that the gap spaces between the rotor and the pump housing are kept wide. Even in the small region of the throttle gaps that rotate slowly near the axis, the gap heights, in comparison to known pumps with hydrodynamic bearing by wedge faces, amount to a multiple of the values given for the known pumps, and the shear stresses that occur are correspondingly slight.
At the maximum rotary speed of the rotor to be expected in operation, which is 3000 min −1 , the circumferential speed in the throttle gap is only γ=1.8 m/s, and for a gap height h of 0.2 mm, a shear degree ã=γ/h of 9000 s −1 is calculated. With the typical viscosity (η) of the blood of 4 mPas, the resultant mean shear stress is τ=γ·η of 36 Nm −2 . This is accordingly one order of magnitude below the limit value of 400 Nm −2 , which according to recent studies is considered critical for blood damage from shear forces (Paul, R., et al, Shear stress related blood damage in laminar couette flow . Artif Organs, 2003. 27(6): p. 517-29).
The cumulative traumatization (BT) of a blood volume (V) upon passage through a zone of high shear stress τ also correlates with the exposure time (t) in accordance with the relation BT˜(V·τ·t). Numerical simulation calculations have shown that the mean passage time of the blood through the entire pump, at a flow rate of 5 l/min, is approximately 100 ms, and a particle remains in the throttle gap for at most approximately 0.3 ms in a shear field of below 40 N/m 2 . The instantaneous blood volume in the throttle gaps is only 15 mm 3 . Such favorable flow-dynamic prerequisites for low blood damage have not been reported before.
Along with the mechanical cell destruction from shear stresses and wall contacts, the activation of the cellular and molecular mechanisms of blood coagulation is a central problem in implantable blood pumps. Clots that block pumps or are carried away as emboli and can cause such complications as strokes and renal infarctions occur preferentially as a result of contact activation at foreign surfaces and also in flow stasis zones and standing eddies. The blood of the invention has no such flow regions; instead, all the chambers that carry blood are constantly purged with a high flow speed and a short dwell time. The surface of all the stationary and rotating components is smooth, and steps and profile sections in the flow direction are avoided. All the preferred versions can be made from biocompatible materials and provided with an anticoagulant coating, such as surface-bonded heparin.
From the mechanisms of the invention, described thus far, for hydrodynamic suspension of the pump rotor, it finally follows that the rotor is positioned centrally in the housing in the axial direction by the effects of the throttle gap. In the radial direction, it requires the additional support of magnetic reluctance forces. In operation, the rotor will dynamically shift, tumble, and run eccentrically. Because of the sufficient spacing from the walls and the fast reaction time of the stabilizing forces, however, it will not hit the wall at any time. The desired mobility of the rotor in the housing is expressly wanted, since only in this inventive combination of the aforementioned characteristics can safe operation, high efficiency, constant purging of all the blood-carrying chambers, and the least blood damage be achieved.
The contactless drive of the pump rotor can be done, in a preferred version, in the form of a permanent-magnetically excited, two-strand electrical disk rotor synchronous machine.
The hydrodynamic suspension of the rotor of the pump dictates a disadvantageously large magnetic air gap between the stator heads for the electrical drive mechanism. This is necessary for receiving all the housing walls, the blood-carrying rotor side chambers, and the rotor itself. The air gap must amount to L=0.1 to 0.15·R, and thus in motor construction makes unusual demands in terms of optimizing the electromechanical efficiency of the drive mechanism.
One criterion that must be met is, with minimum mass of the permanent magnets and hence little axial magnetic rigidity, to generate maximum torque at high electromechanical efficiency, while avoiding resting moments and waviness of the torque.
In the pump of the invention, this problem is solved as follows: The permanent magnets are divided, by the accommodation in the two rotor coverings, and two planes, between which a magnetic short circuit exists via the blade conduit. In a preferred version of the rotor with R=20 mm, d=1 mm and r 3 =16 mm, only 5 g of magnet mass (NdFeB) is then needed, with correspondingly little destabilization of the rotor upon axial deflection.
According to the invention, the two stators can be rotated counter to one another by an amount of from ⅓ to ½ the pole spacing, or in other words, for 6 poles, by 20 to 30 degrees. The permanent magnet regions of the two rotor coverings can also be rotated counter to one another by up to ⅙ the pole spacing, or in other words by up to 10 degrees. Both provisions contribute to suppressing resting moments and waviness of the torque.
A further increase in the electromechanical efficiency, with minimal axial rigidity of the drive mechanism, can be accomplished by optimized pole coverage and of the relative pole coverage of the permanent magnets.
The radial stabilization of the rotor position (translation in the x and y directions) is promoted, but not effected, by the above-described design of the rotor, the rotor side chambers, the circular annular gap, and the spiral conduit that carries the flow away. The radial centering of the rotor is effected by means of magnetic reluctance forces between the permanent magnet regions in the rotor and the head regions of the stator teeth. In pump operation, the stabilizing is further reinforced by the gyroscopic forces acting on the rotor. | The invention relates to a centrifugal pump, especially for blood, comprising a pump rotor which is arranged in a rotational manner and without a bearing in a liquid-tight and gas-tight closed housing, except for at least one inlet opening and at least one outlet opening. The rotor is also the rotor of a drive motor. The rotor is symmetrical with respect to the centre plane thereof and comprises an upper and a lower covering. The rotor and/or the pump housing are formed in such a way that the axial distances between the upper and the lower coverings and the upper and lower housing walls are smaller in the radially inner region of the rotor than in the radially outer region. In the radially inner region of the rotor, each lateral rotor chamber comprises a flow-restrictor gap which, when in operation, influences back flows oriented in a radially inward manner in the lateral rotor chambers, such that during an axial deflection of the rotor above and below the rotor, various pressure distributions appear, enabling forces acting upon the predominant surface of the coverings to be produced, the forces bringing about an axial stabilisation of the rotor and acting, in the same manner, against tilting of the rotor inside the housing. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to the technical field of computer-aided information management, and concerns more specifically a method and an apparatus for data processing according to the preamble to claim 1 and claim 8 , respectively, for accomplishing increased protection against unauthorised processing of data.
BACKGROUND ART
[0002] In the field of computer-aided information management, it is strongly required that the protection against unauthorised access of data registers be increased, especially against violation of the individual's personal integrity when setting up and keeping personal registers, i.e. registers containing information on individuals. In particular, there are regulations restricting and prohibiting the linking and matching of personal registers. Also in other fields, such as industry, defence, banking, insurance, etc, improved protection is desired against unauthorised access to the tools, databases, applications etc. that are used for administration and storing of sensitive information.
[0003] WO95/15628, which has the same owner as the present application, discloses a method for storing data, which results in increased possibilities of linking and matching with no risk of reduced integrity. The method, which is illustrated schematically in FIGS. 1 and 2 on the enclosed drawing sheets, concerns storing of information comprising on the one hand an identifying piece of information or original identity OID, for instance personal code numbers Pcn and, on the other hand, descriptive information DI. The information OID+DI is stored as records P in a database O-DB according to the following principle:
Step 1 OID (Pcn) is encrypted by means of a first, preferably non-reversible algorithm ALG 1 to an update identity UID; Step 2 UID is encrypted by means of a second, reversible algorithm ALG 2 to a storage identity SID; Step 3 SID and DI are stored as a record P in the database O-DB, SID serving as a record identifier; Step 4 At predetermined times, an alteration of SID in all or selected records P is accomplished by SID of these records being decrypted by means of a decrypting algorithm ALG 3 to UID, whereupon UID is encrypted by means of a modified second, reversible algorithm or ALG 2 ′ to a new storage identity SID′, which is introduced as a new record identifier in the associated record P as replacement for previous SID. This results in a security-enhancing “floating” alteration of SID of the records.
[0008] For a closer description of the details and advantages of this encrypting and storing method, reference is made to WO95/15628, which is to be considered to constitute part of the present description. The storing principle according to steps 1-4 above is below referred to as PTY, which is an abbreviation of the concept PROTEGRITY which stands for “Protection and Integrity”.
[0009] A detailed technical description of PTY is also supplied in the document “PROTEGRITY (ASIS) Study 2”, Ver. 1.2, 1 Mar. 1996, by Leif Jonson. Also this document is to be considered to constitute part of the present description.
[0010] In the technical field at issue, so-called shell protections, however, are today the predominant method of protection. Shell protection comprises on the one hand the external security (premises) and, on the other hand, an authorisation check system ACS with user's passwords for controlling the access. ACS is used as shell protection for main frames, client/server systems and PC, but it does not give full protection and the information at issue can often relatively easily be subjected to unauthorised access. This protection has been found more and more unsatisfactory since, to an increasing extent, “sensitive” information is being stored, which must permit managing via distribution, storing and processing in dynamically changing environments, especially local distribution to personal computers. Concurrently with this development, the limits of the system will be more and more indistinct and the effect afforded by a shell protection deteriorates.
SUMMARY OF THE INVENTION
[0011] In view of that stated above, the object of the present invention is to provide an improved method for processing information, by means of which it is possible to increase the protection against unauthorised access to sensitive information.
[0012] A special object of the invention is to provide a technique for data processing or managing, which makes it possible for the person responsible for the system, the management of the organisation etc. to easily establish and continuously adapt the user's possibility of processing stored information that is to be protected.
[0013] A further object of the invention is to provide a technique for data processing which offers protection against attempts at unauthorised data processing by means of non-accepted software.
[0014] One more object of the invention is to provide a technique for data processing according to the above-mentioned objects, which can be used in combination with the above-described PTY principle, for providing a safety system with an extremely high level of protection.
[0015] These and other objects of the invention are achieved by the method according to claim 1 and the apparatus according to claim 8 , preferred embodiments of the invention being stated in the dependent claims.
[0016] Thus, the invention provides a method for processing of data that is to be protected, comprising the measure of storing the data as encrypted data element values of records in a first database (O-DB), each data element value being linked to a corresponding data element type.
[0017] The inventive method is characterised by the following further measures:
[0018] storing in a second database (IAM-DB) a data element protection catalogue, which for each individual data element type contains one or more protection attributes stating processing rules for data element values, which in the first database are linked to the individual data element type,
[0019] in each user-initiated measure aiming at processing of a given data element value in the first database, initially producing a compelling calling to the data element protection catalogue for collecting the protection attribute/attributes associated with the corresponding data element type, and compellingly controlling the processing of the given data element value in conformity with the collected protection attribute/attributes.
[0020] In the present application the following definitions are used:
“Processing” may include all kinds of measures which mean any form of reading, printing, altering, coding, moving, copying etc. of data that is to be protected by the inventive method. “Data element type” concerns a specific type of data having a meaning as agreed on. “Data element value” concerns a value which in a given record specifies a data element type. “Record” concerns a number of data element values which belong together and which are linked to the respective data element types, optionally also including a record identifier, by means of which the record can be identified. Example:
[0000]
DATA ELEMENT TYPE
RECORD ID
SOCIAL ALLOWANCE
CAR
XXXX XXXXX
encrypted data element value
encrypted data
element value
YYYY YYYYY
encrypted data element value
encrypted data
element value
“Protection attribute indicating rules of processing” may concern:
data stored in the data element protection catalogue and providing complete information on the rule or rules applying to the processing of the corresponding data element, and/or data stored in the data element protection catalogue and requiring additional callings to information stored in some other place, which, optionally in combination with the protection attributes, states the processing rules involved.
“Collection of protection attributes” may concern:
collection of the protection attributes in the form as stored in the data element protection catalogue, and collection of data recovered from the protection attributes, for instance by decryption thereof.
“Encryption” may concern any form of encryption, tricryption, conversion of coding of plain-text data to non-interpretable (encrypted) data, and is especially to concern also methods of conversion including hashing.
[0032] The inventive method offers a new type of protection, which differs essentially from the prior-art shell protection and which works on the cell or data element level. Each data element type used in the records in the first database is thus associated with one or more protection attributes, which are stored in a separate data element protection catalogue and which protection attributes state rules of how to process the corresponding data element values. It should be particularly noted that the calling to the data element protection catalogue is compelling. This means that in a system, in which the method according to the invention is implemented, is such as to imply that a user, who for instance wants to read a certain data element value in a given record in the first database, by his attempt at access to the data element value automatically and compellingly produces a system calling to the data element protection catalogue in the second database for collecting the protection attributes associated with the corresponding data element types. The continued processing procedure (reading of data element value) of the system is also controlled compellingly in accordance with the collected protection attribute/attributes applying to the corresponding data element types.
[0033] The term “data element protection catalogue” and the use thereof according to the invention must not be confused with the known term “active dictionary”, which means that, in addition to an operative database, there is a special table indicating different definitions or choices for data element values in the operative database, for instance that a data element value “yellow” in terms of definition means a colour code which is within a numeric interval stated in such a reference table.
[0034] Preferably, the processing rules stated by the protection attributes are inaccessible to the user, and the read or collected protection attributes are preferably used merely internally by the system for controlling the processing. A given user, who, for instance, wants to read information stored in the database regarding a certain individual, thus need not at all be aware of the fact that certain protection attributes have been activated and resulted in certain, sensitive information for this individual being excluded from the information that is made available on e.g. a display. Each user-initiated measure aiming at processing of data element values thus involves on the one hand a compelling calling to the data element protection catalogue and, on the other hand, a continued processing which is compellingly subjected to those processing rules that are stated by the protection attributes, and this may thus be accomplished without the user obtaining information on what rules control the processing at issue, and especially without the user having any possibility of having access to the rules.
[0035] By altering, adding and removing protection attributes in the data element protection catalogue, the person responsible for the system or an equivalent person may easily determine, for each individual data element type, the processing rules applying to data element values associated with the individual data element type and thus easily maintain a high and clear safety quality in the system.
[0036] According to the invention, it is thus the individual data element (date element type) and not the entire register that becomes the controlling unit for the way in which the organisation, operator etc. responsible for the system has determined the level of quality, responsibility and safety regarding the management of information.
[0037] To obtain a high level of protection, the data element protection catalogue is preferably encrypted so as to prevent unauthorised access thereto.
[0038] As preferred protection attributes, the present invention provides the following possibilities, which, however, are to be considered an incomplete, exemplifying list:
1. Statement of what “strength” or “level” (for instance none, 1, 2 . . . ) of encryption is to be used for storing the corresponding data element values in the database. Different data element values within one and the same record may thus be encrypted with mutually different strength. 2. Statement of what “strength” or “level” (for instance none, 1, 2, . . . ) of encryption is to be used for the corresponding data element values if these are to be transmitted on a net. 3. Statement of program and/or versions of program that are authorised to be used for processing the corresponding data element values. 4. Statement of “owner” of the data element type. Different data element values within one and the same record can thus have different owners. 5. Statement of sorting-out rules for the corresponding data element values, for instance, statement of method and time for automatic removal of the corresponding data element values from the database. 6. Statement whether automatic logging is to be made when processing the corresponding data element values.
[0045] According to a specially preferred embodiment of the invention, the above-described PTY storing method is used for encryption of all data that is to be encrypted in both the database (i.e. the data element values) and the data element protection catalogue (i.e. the protection attributes). In the normal case where each record has a record identifier (corresponding to SID above), preferably also the record identifier is protected by means of PTY. Specifically, a floating alteration of the record identifiers in both the operative database and the data element protection catalogue can be made at desired intervals and at randomly selected times, in accordance with the above-described PTY principle. In the preferred embodiment, especially the encapsulated processor which is used for the PTY encryption can also be used for implementation of the callings to the data element protection catalogue and the procedure for processing according to the collected protection attributes.
[0046] The invention will now be explained in more detail with reference to the accompanying drawings, which schematically illustrate the inventive principle implemented in an exemplifying data system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 (prior art) schematically shows the principle of storing of data information according to the PTY principle in WO95/15628.
[0048] FIG. 2 (prior art) schematically shows the principle of producing floating storing identities according to the PTY principle in WO95/15628.
[0049] FIG. 3 schematically shows a computer system for implementing the method according to the invention.
[0050] FIG. 4 schematically shows the principle of data processing according to the invention with compelling callings to a data element protection catalogue.
[0051] FIG. 5 shows an example of a display image for determining of protection attributes in the data element protection catalogue.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0052] In the following, the designation IAM (which stands for Information Assets Manager) will be used for the components and applications which in the embodiment are essential to the implementation of the invention.
[0053] Reference is first made to FIG. 3 , which schematically illustrates a data managing system, in which the present invention is implemented and in which the following databases are included for storing information, in this example person-related information:
An open database P-DB which contains generally accessible data, such as personal name, article name, address etc. with the personal code number Pcn as plain text as record identifier; An operative database O-DB, which contains data that is to be protected. Encrypted identification, in this case an encrypted personal code number, is used as record identifier (=storage identity SID). O-DB is used by authorised users for processing of individual records, such as reading and update; An archive-database A-DB, which contains data transferred (sorted out) from the operative database O-DB and which is used for statistic questions, but not for questions directed to individual records. The transfer from O-DB to A-DB may take place in batches. A database IAM-DB, which is a database essential to the implementation of the invention. This database contains a data element protection catalogue with protection attributes for such data element types as are associated with data element values in records in the operative database O-DB. This database IAM-DB is preferably physically separated from the other O-DB and is inaccessible to the user. However, two or more sets of the data element protection catalogue may be available: on the one hand an original version to which only an authorised IAM operator has access and, on the other hand, a copy version which imports the data element protection catalogue from the original version and which may optionally be stored on the same file storage as the operative database O-DB. The two versions may be remote from each other, for instance be located in two different cities.
[0058] The data system in FIG. 3 further comprises a hardware component 10 , a control module 20 (IAM-API), and a program module 30 (PTY-API). The function of these three components will now be described in more detail.
Hardware Component 10
[0059] The hardware component 10 acts as a distributed processor of its own in a computer. It has an encapsulation that makes it completely tamper-proof, which means that monitoring by so-called trace tools will not be possible.
[0060] The hardware component 10 can as an independent unit perform at least the following functions:
Creating variable, reversible and non-reversible encrypting algorithms for the PTY encryption and providing these algorithms with the necessary variables; Initiating alterations of storage identities (SID) in stored data according to PTY, on the one hand data in O-DB and, on the other hand, data in the data element protection catalogue of IAM-DB; Storing user authorisations having access to records in O-DB; and Linking original identities OID to the correct record in O-DB.
Control Module 20 (IAM-API)
[0065] The control module controls the handling of the types of data protection that the system can supply.
[0066] The control module carries out the processing requested via API (Application Program Interface) programming interface.
Program Module 30 (PPTY-API) 30
[0067] The program module (PTY-API) 30 handles the dialogue between the application 40 involved (including ACS) and the hardware component 10 . This module may further log events and control sorting out/removal of data from the operative database O-DB.
[0068] Reference is now made to FIG. 4 , which illustrates the same four databases (P-DB, O-DB, A-DB, IAM-DB) as in FIG. 3 and which schematically illustrates how the processing of individual data elements are, according to the invention, controlled according to the rules that are stated by protection attributes in the data element protection catalogue, which is stored in the database IAM-DB.
[0069] The data that is to be stored concerns in this example a certain individual and contains: (1) generally accessible data such as name and address, (2) identifying information, such as personal code number (Pcn), and (3) descriptive information (DI). The generally accessible data name and address is stored together with personal code number (Pcn) in the open database P-DB, said storage being performable as plain text since this information is of the type that is generally accessible.
[0070] For storing the identifying information in combination with the descriptive information DI, the following steps will, however, be made, in which the following designations are used to describe encrypting and decrypting algorithms. Generally speaking, the encrypting and decrypting algorithms can be described as follows:
[0000] F Type (Random number, Input data)=Results
[0000] wherein:
F designates a function. Type indicates the type of function as follows:
F KIR =Non-reversible encrypting algorithm F KR =Reversible encrypting algorithm F DKR =Decrypting algorithm
Random number
represents one or more constants and/or variables included in the function F.
Input data
are the data to be encrypted or decrypted, and
Results indicate a unique function value for a given function
Step 1 Division of the Information
[0000]
Identifying information is separated from descriptive information;
Step 2 Preparation of Storage Identity SID:
[0000]
An original identity OID is selected based on the identifying information. OID is here selected to be equal to the personal code number Pcn of the individual. OID is encrypted by means of a non-reversible encrypting algorithm ALG 1 , prepared randomly by the hardware component 10 , to an update identity UID as follows:
[0000] ALG1: F KIR (Random number, OID)=UID ALG 1 is such that attempts at decryption of UID to OID result in a great number of identities, which makes it impossible to link a specific UID to the corresponding OID. Then UID is encrypted by means of a reversible algorithm ALG 2 , which is also produced at random by the hardware component 10 , for generating a storage identity SID as follows:
[0000] ALG2: (Random number, UID)=SID ALG 2 is such that there exists a corresponding decrypting algorithm ALG 3 , by means of which SID can be decrypted in order to recreate UID. The storage identity SID is used, as described in step 4 above, as encrypted record identifier when storing encrypted data element values DV in the operative database O-DB.
Step 3 Production of Encrypted Data Element Values DV:
[0000]
The descriptive information DI associated with the original identity OID is converted into one or more encrypted data element values DV linked to a data element type DT each.
The encryption takes place as described below with a reversible encryption function F KR , which like the algorithms ALG 1 and ALG 2 above is also produced at random by the hardware component 10 . The invention is distinguished by a compelling calling here being sent to the data element protection catalogue in the database IAM-DB for automatic collection of the protection attribute which is linked to the data element type at issue and which indicates “strength” or degree with which the encryption of the descriptive data is to be performed so as to generate the data element value DV.
The table, which in FIG. 4 is shown below the database IAM-DB, symbolises an exemplifying content of the data element protection catalogue, here designated DC. As an example, it may here be assumed that the protection function Func 1 corresponds to “degree of encryption”. If the descriptive information DI at issue is to be stored as a data element value associated with the specific data element type DT 1 in the data element protection catalogue, the protection attribute “5” registered in the data element protection catalogue is collected automatically in this case. The descriptive information DI at issue will thus, automatically and compellingly, be encrypted with the strength “5” for generating an encrypted data element value DV as follows:
[0000] F KR (Random number, DI)=encrypted data element value DV For storing a less sensitive data element, for instance a data element of the data element type DT 3 , the compelling calling to the data element protection catalogue in IAM-DB would instead have resulted in the protection attribute “no” being collected, in which case no encryption would have been made on the descriptive data at issue, which then could be stored as plain text in the operative database ODB.
Step 4 Storing of Records in the Operative Database O-DB:
[0000]
The encrypted storage identity SID according to step 2 in combination with the corresponding encrypted data element value or data element values DV according step 3 are stored as a record in the operative database O-DB.
[0092] As appears from the foregoing, a stored information record P has the following general appearance:
[0000]
Descript. information in
the form of encrypted
data element values
Storage identity (SID)
DV1
DV2
DV3
DV4
[0093] The original identity OID is encrypted according to the PTY principle in two steps, of which the first is non-reversible and the second is reversible. Thus, it is impossible to store the descriptive information DI along with a storage identity SID that never can be linked to the original identity OID, as well as to create “floating”, i.e. which change over time, storage identities SID while retaining the possibility of locating, for a specific original identity OID, the associated descriptive information DI stored.
[0094] The descriptive data DI is stored in accordance with protection attributes linked to each individual data element. This results in a still higher level of protection and a high degree of flexibility as to the setting up of rules, and continuous adaptation thereof, of how sensitive data is allowed to be used and can be used, down to the data element level.
[0095] To increase the level of protection still more, the data element protection catalogue DC is preferably stored in IAM-DB in encrypted form in accordance with the PTY principle, in which case for instance the data element types correspond to the above storage identity and the protection attributes correspond to the descriptive information or data element values above, as schematically illustrated in FIG. 4 . This efficiently prevents every attempt at circumventing the data element protection by unauthorised access and interpretation of the content of the data element protection catalogue.
[0096] In the illustrated embodiment, PTY can thus have the following functions:
Protecting the original identity OID in encrypted form (SID) on the operative database O-DB (as is known from said WO95/15628), Protecting information in IAM-DB, particularly the protection attributes of the data element protection catalogue and the associated record identifier, and Protecting descriptive information DI in the form of encrypted data element values DV for the data element types that have the corresponding protection activated in the data element protection catalogue, and in accordance with the corresponding protection attributes.
Functionality Protection
[0100] In the above embodiment of the procedure for inputting data in the operative database O-DB, only “degree of encryption” has so far been discussed as data element protection attribute in the data element protection catalogue DC. However, this is only one example among a number of possible protection attributes in the data element protection catalogue, which normally offers a plurality of protection attitudes for each data element. Preferred protection attributes have been indicated above in the general description.
[0101] A particularly interesting protection attribute is “protected programs”. The use of this data element protection attribute means that the data system may offer a new type of protection, which is here called “functionality protection” and which means that only accepted or certified programs are allowed to be used and can be used in the system in the processing of data. It should be noted that this type of protection is still, according to the invention, on the data element level.
[0102] Now assume for the purpose of illustration that Func 2 in the data element protection catalogue DC in FIG. 4 corresponds to this protection attribute and that data elements of the data element type DT 1 and DT 2 , respectively, are only allowed to processed with the accepted applications or programs P 1 and P 2 , respectively. Unauthorised handling of the corresponding data elements by means of, for instance, a different program P 3 , or a modified version P 1 ′ of P 1 , should be prevented. As protection attribute in the data element protection catalogue, data identifying P 1 and P 2 is therefore stored. In a preferred example, an encryptographic check sum P 1 * and P 2 *, respectively, is created, in a manner known per se, based on every accepted program P 1 and P 2 , respectively. These check sums may be considered to constitute a unique fingerprint of the respective accepted programs, and these fingerprints can be stored as protection attributes in the data element protection catalogue as illustrated schematically in FIG. 4 . It should however be noted that such check sums for accepted programs can optionally be stored in a data element protection catalogue of their own for registering of accepted programs, separately from the data element protection catalogue with protection attributes for encryption strength.
[0103] If the last-mentioned type of protection “protected programs” is used, it should also be noted that the system, in connection with a user-initiated measure aiming at processing of a given data element, for instance inputting a new data element value in a certain record, need not carry out a complete examination of all programs accepted in the system. If, for instance, the user tries to use a program P 3 for inputting in the operative database O-DB a new data element value, a compelling calling is sent to the data element protection catalogue in connection with the corresponding data element type, for instance DT 1 . The associated protection attribute P 1 * is then collected from the data element protection catalogue, which means that such a data element value is only allowed to be stored by means of the program P 1 . The attempt at registering the data element value by means of the program P 3 would therefore fail.
[0104] By periodic use of the above-described functionality protection, it is possible to reveal and/or prevent that an unauthorised person (for instance a “hacker”) breaks into the system by means of a non-accepted program and modifies and/or adds descriptive data in such a manner that the descriptive data will then be identifying for the record. The data element values are thus not allowed to become identifying in the operative database O-DB.
Traceability/Logging
[0105] “Logging” or “traceability” is another type of protection which according to the invention can be linked to a data element type in the data element protection catalogue. If this protection is activated for a certain data element type, each processing of the corresponding data element values in the operative database O-DB will automatically and compellingly result in relevant information on the processing (“user”, “date”, “record”, “user program” etc.) being logged in a suitable manner, so that based on the log, it is possible to investigate afterwards who has processed the data element values at issue, when, by means of which program etc.
[0000] Reading of Data from the Operative Database O-DB
[0106] In connection with a user-initiated measure aiming at reading/altering data element values in the stored records in the operative database O-DB, the following steps are carried out, which specifically also comprise a compelling calling to the data element protection catalogue and “unpacking” of the data which is controlled automatically and compellingly by collected protection attributes.
Step 1 The record is identified by producing the storage identity SID at issue based on the original identity OID, (Pcn) that is associated with the data element value DV which is to be read, as follows
[0000] F KR (F KIR (OID))=SID Step 2 When the record has been found by means of SID, the encrypted data element value DV (i.e. the encrypted descriptive data that is to be read) is decrypted as follows by means of a decrypting algorithm F DKR :
[0000] F DKR (DV)=descriptive data (plain text) The carrying out of this decryption of the data element value, however, requires that the encryption-controlling protection attribute of the data element is first collected by the system from the data element protection catalogue DC, i.e. the attribute indicating with which strength or at which level the data element value DV stored in O-DB has been encrypted. Like in the above procedure for inputting of data in O-DB, also when reading, a compelling calling thus is sent to the data element protection catalogue DC for collecting information which is necessary for carrying out the processing, in this case the unpacking. It will be appreciated that such a compelling calling to the data element protection catalogue DC, when making an attempt at reading, may result in the attempt failing, wholly or partly, for several reasons, depending on the protection attribute at issue, which is linked to the data element value/values that is/are to be read. For instance, the attempt at reading may be interrupted owing to the user trying to use a non-accepted program and/or not being authorised to read the term involved.
[0111] If the data element protection catalogue is encrypted, the decoding key can be stored in a storage position separate from the first and the second database.
[0112] FIG. 5 shows an example of a user interface in the form of a dialogue box, by means of which a person responsible for IAM, i.e. a person responsible for security, may read and/or alter the protection attributes stated in the data element protection catalogue. In the Example in FIG. 5 , the data element types “Housing allowance” and “Social allowance” have both been provided with protection attributes concerning encryption, sorting out, logging and owner. Moreover, registration of authorised users and protected programs linked to the data element type “Social allowance” has taken place in submenus. | A method and an apparatus for processing data provides protection for the data. The data is stored as encrypted data element values (DV) in records (P) in a first database (0-DB), each data element value being linked to a corresponding data element type (DT). In a second database (IAM-DB), a data element protection catalogue (DC) is stored, which for each individual data element type (DT) contains one or more protection attributes stating processing rules for data element values (DV), which in the first database (0-DB) are linked to the individual data element type (DT). In each user-initiated measure which aims at processing a given data element value (DV) in the first database (0-DB), a calling is initially sent to the data element protection catalogue for collecting the protection attribute/attributes associated with the corresponding data element types. The user's processing of the given data element value is controlled in conformity with the collected protection attribute/attributes. | 8 |
RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 09/961,751 filed Sep. 24, 2001, which is a continuation of U.S. patent application Ser. No. 09/450,966 filed Nov. 30, 1999, now abandoned. Each of U.S. patent application Ser. Nos. 09/961,751 and 09/450,966 is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is broadly concerned with light attenuating compounds for incorporation into photolithographic compositions (e.g., anti-reflective coatings and contact or via hole fill compositions) utilized in the manufacturing of microdevices. More particularly, the light attenuating compounds are non-aromatic and are especially useful for absorbing light at shorter wavelengths (e.g., 248 nm). The compounds can be physically incorporated into the particular composition, or alternately, can be chemically bonded to a polymer binder already present in the composition. The compounds of the invention comprise conjugated aliphatic and alicyclic moieties which meet the necessary light absorbency requirements for the composition while enhancing the plasma etch rate of the composition when compared to prior art aromatic dyes.
[0004] 2. Description of the Prior Art
[0005] A frequent problem encountered by photoresists during the manufacturing of semiconductor devices is that activating radiation is reflected back into the photoresist by the substrate on which it is supported. Such reflectivity tends to cause blurred patterns which degrade the resolution of the photoresist. Degradation of the image in the processed photoresist is particularly problematic when the substrate is non-planar and/or highly reflective. One approach to address this problem is the incorporation of an anti-reflective dye either into the photoresist layer, into a contact or via hole fill composition, into a bottom anti-reflective coating (BARC), or as a separate layer adjacent the photoresist layer.
[0006] Prior art BARC compositions usually contain aromatic anti-reflective dyes which attenuate light that would otherwise reflect from the substrate during photoresist exposure. For example, anthracene and naphthalene derivatives are typically the preferred dyes for use at 248 nm exposing wavelengths. Dyes comprising a benzene ring with at least one conjugated substituent are widely used in BARC's which operate at 365 nm, while dyes comprising a benzene ring without conjugated substituents have ample absorptivity to satisfy most 193 nm applications.
[0007] Aromatic dyes have been preferred for BARC applications because of their high light absorbency per unit mass as well as their wide availability, easy preparation, and high chemical stability. While aromatic dyes are useful for achieving high film optical density, they limit the plasma etch rate of the BARC compositions by virtue of their chemical stability. Aromatic dyes require considerably more energy for decomposition than do the polymer binders (which are typically non-aromatic) used in the BARC compositions. As a result, the composite etch rate is highly dependent on the aromatic character of the dyes.
[0008] U.S. Pat. No. 4,719,166 to Blevins et al. discloses the use of certain butadienyl dyes in a photoresist layer, an anti-reflective layer, or a planarizing layer for protecting photoresist elements against reflection of activating radiation from the substrate. However, the dyes of the '166 patent are not attached to the backbone of a polymer binder, thus permitting them to readily solubilize in the photoresist, often leading to pattern degradation. Furthermore, current technology continues to require increasingly complex circuitry be imprinted on chips of decreasing size. These smaller chips require shorter wavelengths (e.g., 248 nm) be used during photoresist exposure. The dyes of the '166 patent are useful for absorbing light only at 365 nm exposure wavelengths, making them unsuitable for use in the manufacturing of most current microdevices.
[0009] There is a need for a compound which can effectively attenuate light at shorter wavelengths and which does not inhibit the etch rate of the particular BARC or contact or via hole fill composition in which it is utilized.
SUMMARY OF THE INVENTION
[0010] The present invention fills this need by providing light attenuating compounds for BARC compositions, contact or via hole fill compositions, and other microdevice manufacturing compositions which do not inhibit the etch rate of the composition. Furthermore, the inventive compounds are useful for absorbing light at shorter wavelengths.
[0011] In more detail, the light attenuating compounds are non-aromatic and can be formulated to absorb light at the desired wavelength. Advantageously, the compounds are also useful for absorbing light at wavelengths of less than about 300 nm, and preferably less than about 250 nm (e.g., for 248 nm applications).
[0012] As used herein, non-aromatic refers to compounds or moieties of compounds which either:
[0013] (1) do not include a benzene ring; or
[0014] (2) (a) have non-planar carbon skeletons; and
[0015] (b) do not contain (4n+2)π electrons, where n=0, 1, 2, 3, etc. (i.e., do not obey Hückel's Rule as described in Solomons, T. W. Graham, Fundamentals of Organic Chemistry , 3rd ed., John Wiley & Sons, Inc. (1990)).
[0016] The light attenuating compounds of the invention comprise moieties having general structural formulas (set forth in detail below). Preferably, these compounds include one or more reactive groups selected from the group consisting of COOH, OH, CONH 2 , CONHR, CH 2 X groups, and mixtures thereof, where R is selected from the group consisting of hydrogen, alkyls (preferably C 1 -C 4 branched and unbranched), and heteroalkyls, and X is a halogen.
[0017] The light attenuating compounds can be incorporated into the particular photolithographic composition either physically (i.e., as a mixture) or by chemically attaching the light attenuating compound to the polymer binder or resin present in the composition (either to a functional group on the binder or directly to the backbone of the binder). In situations where the light attenuating compound is attached to the polymer binder, a linkage unit can be used as an intermediate for securing the light attenuating compound to the binder. That is, the light attenuating compound can be attached to a linkage unit which in turn is attached to the polymer binder (either to a functional group on the binder or to the binder backbone). Examples of suitable linkage units are those which comprise a moiety selected from the group consisting of alkyls (preferably C 1 -C 4 branched and unbranched), acyclic heteroalkyls, non-aromatic cyclic alkyls (preferably C 3 -C 6 ) and non-aromatic cyclic heteroalkyls.
[0018] In another embodiment, the light attenuating compounds can be polymerized alone so as to directly form the polymer binder utilized in the particular photolithographic composition while simultaneously acting as a light absorber. Thus, in these applications an additional polymer binder would not be necessary.
[0019] In applications where a polymer binder other than the light attenuating compound is present in the composition, the binder should be dissolved in a solvent system (either single or multiple solvents). The particular polymer binders and solvent systems utilized are readily ascertainable by those skilled in the art. Examples of suitable polymer binders include polyesters, polyacrylates, polyheterocyclics, polyetherketones, polyhydroxystyrene, polycarbonates, polyepichlorohydrin, polyvinyl alcohol, oligomeric resins (such as crown ethers, cyclodextrins, epoxy resins), and mixtures of the foregoing. Examples of preferred solvents for use in the solvent system include alcohols, ethers, glycol ethers, amides, esters, ketones, water, propylene glycol monomethyl ether (PGME), propylene glycol monomethyl ether acetate (PGMEA), ethyl lactate, and PCBTF (p-chlorobenzotrifluoride).
[0020] Incorporating light attenuating compounds into photolithographic compositions in accordance with the invention will not increase the etch rate of the composition as is the case with prior art compositions comprising aromatic dyes. Thus, when practicing the instant invention, the etch rate of the photolithographic composition will be at least about 4000 Å/minute, where a mixture of HBr and O 2 is the etchant gas.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] While the inventive light attenuating compounds broadly include non-aromatic dyes, and particularly non-aromatic dyes which absorb light at shorter wavelengths, in preferred embodiments the compounds include one or more of the following moieties.
[0022] Generally speaking, the light attenuating compounds should include at least one double bond in conjugation with at least one electron-withdrawing group (EWG). One such structure is shown below in Formula I.
[0023] where:
[0024] each R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0025] in structure A, where EWG and R 2 do not form a cyclic unit:
[0026] EWG is a non-aromatic electron-withdrawing group such as a carbonyl, cyano, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group; and
[0027] R 2 is non-aromatic and may be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, cyano, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group;
[0028] in structure B, where EWG and R 2 form a cyclic electron-withdrawing unit, the cyclic unit preferably comprises a C═O, C═S, or a C═N at a first carbon atom, and: a C═O or a C═N attached to a carbon atom at least two carbon atoms away from the first carbon atom; or an O, S, or N as a member of the ring at least two positions away from the first carbon atom; and
[0029] (1) and (2) refer to the respective double-bonded carbon atoms.
[0030] Examples of particularly preferred structures B of Formula I where EWG and R 2 form a cyclic electron-withdrawing unit include the following:
[0031] where R 1 is non-aromatic and may individually be hydrogen, or an acrylic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl.
[0032] In another embodiment, the light attenuating compounds include at least one EWG across a double bond from an electron donating group (EDG) as shown in Formula II.
[0033] where:
[0034] R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0035] EDG is an electron-donating group such as H 3 CO—, —OH, or R x R Y N—, where each of R x and R y is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 2 ) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0036] in structure A, where EWG and R 2 do not form a cyclic unit:
[0037] EWG is a non-aromatic electron-withdrawing group such as a carbonyl, cyano, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group; and
[0038] R 2 is non-aromatic and may be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, cyano, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group;
[0039] in structure B, where EWG and R 2 form a cyclic electron-withdrawing unit, the cyclic unit preferably comprises a C═O, C═S, or a C═N at a first carbon atom, and: a C═O or a C═N attached to a carbon atom at least two carbon atoms away from the first carbon atom; or an O, S, or N as a member of the ring at least two positions away from the first carbon atom; and
[0040] (1) and (2) refer to the respective double-bonded carbon atoms.
[0041] Examples of particularly preferred structures B of Formula II where EWG and R 2 form a cyclic electron-withdrawing unit include the following:
[0042] where R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl.
[0043] In another embodiment, the light attenuating compounds include two conjugated double bonds in series with at least one EWG (see Formula III) or with two EWG's (see Formula IV). The structures shown in Formulas III and IV are particularly useful at 248 nm or 365 nm wavelength applications, depending upon the selection of R and EWG.
[0044] where:
[0045] each R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0046] in structure A, where EWG and R 2 do not form a cyclic unit:
[0047] EWG is a non-aromatic electron-withdrawing group such as a carbonyl, cyano, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group; and
[0048] R 2 is non-aromatic and may be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, cyano, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group;
[0049] in structure B, where EWG and R 2 form a cyclic electron-withdrawing unit, the cyclic unit preferably comprises a C═O, C═S, or a C═N at a first carbon atom, and: a C═O or a C═N attached to a carbon atom at least two carbon atoms away from the first carbon atom; or an O, S, or N as a member of the ring at least two positions away from the first carbon atom; and
[0050] (1)-(4) refer to the respective double-bonded carbon atoms.
[0051] Examples of particularly preferred structures B of Formula III where EWG and R 2 form a cyclic electron-withdrawing unit include the following:
[0052] where R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl.
[0053] where:
[0054] each R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0055] EWG is a non-aromatic electron-withdrawing group such as a carbonyl, cyano, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group; and
[0056] (1)-(4) refer to the respective double-bonded carbon atoms.
[0057] In another embodiment the light attenuating compounds include an EWG coupled with an EDG across a conjugated double bond system. An example of this structure is shown in Formula V.
[0058] where:
[0059] each R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0060] EDG is an electron-donating group such as H 3 CO—, —OH, or R x R y N—, where each of R x and R y is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 2 ) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0061] in structure A, where EWG and R 2 do not form a cyclic unit:
[0062] EWG is a non-aromatic electron-withdrawing group (other than cyano groups) such as a carbonyl, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group, and R 2 is non-aromatic and may be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, cyano, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group; or
[0063] EWG is a cyano group, and R 2 is non-aromatic and may be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0064] in structure B, where EWG and R 2 form a cyclic electron-withdrawing unit, the cyclic unit preferably comprises a C═O, C═S, or a C═N at a first carbon atom, and: a C═O or a C═N attached to a carbon atom at least two carbon atoms away from the first carbon atom; or an O, S, or N as a member of the ring at least two positions away from the first carbon atom; and
[0065] (1)-(4) refer to the respective double-bonded carbon atoms.
[0066] Examples of particularly preferred structures B of Formula V where EWG and R 2 form a cyclic electron-withdrawing unit include the following:
[0067] where R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl.
[0068] Of course, those skilled in the art will appreciate that light attenuating compounds in accordance with the invention can include mixtures of the foregoing Formulas I-V in the particular photolithographic composition.
[0069] In another embodiment, the foregoing structures can be dimerized to form new compositions which are preferably incorporated into photolithographic compositions to absorb light, thus minimizing or eliminating the reflectance from the substrate. These dimerized structures are shown in Formulas VI-VIII.
[0070] where:
[0071] each R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0072] each R 3 may individually be R 1 or
[0073] where each R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, and where the (*) represents the double-bonded carbon atom (1) or (4);
[0074] each EWG is a non-aromatic electron-withdrawing group such as a carbonyl, cyano, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group;
[0075] each R 2 is non-aromatic and may individually be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, cyano, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group;
[0076] R 4 is a divalent, non-aromatic-containing bridging group such as —(CH 2 ) n —, dimethylenecyclohexyl (—CH 2 —C 6 H 4 —CH 2 —), —CH 2 CH 2 —O—CH 2 CH 2 —, or other acyclic (preferably C 1 -C 4 , branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyls or heteroalkyls; and
[0077] (1)-(4) refer to the respective double-bonded carbon atoms.
[0078] where:
[0079] each R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0080] each R 2 is non-aromatic and may individually be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, cyano, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group;
[0081] each R 3 may individually be EDG, or
[0082] where each R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl; EDG is an electron-donating group such as H 3 CO—, —OH, or R x R y N—, where each of R x and R y is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 2 ) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl; and where the (*) represents the double-bonded carbon atom (1) or (4);
[0083] R 4 is a divalent, non-aromatic-containing bridging group such as —(CH 2 ) n —, dimethylenecyclohexyl (—CH 2 —C 6 H 4 —CH 2 —), —CH 2 CH 2 —O—CH 2 CH 2 —, or other acyclic (preferably C 1 -C 4 , branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyls or heteroalkyls;
[0084] each EWG is a non-aromatic electron-withdrawing group such as a carbonyl, cyano, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group; and
[0085] (1)-(4) refer to the respective double-bonded carbon atoms.
[0086] where:
[0087] each R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0088] where each R 3 may individually be an EWG,
[0089] in structure A of Formula VIII, in situations where R 3 is an EWG or structure C (i.e., EWG and R 2 do not form a cyclic unit):
[0090] each EWG is a non-aromatic electron-withdrawing group (other than cyano groups) such as a carbonyl, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group, and each R 2 is non-aromatic and may individually be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group; or
[0091] EWG is a cyano group, and each R 2 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0092] in structure B of Formula VIII, and in structure A of Formula VIII where R 3 is structure D (i.e., in situations where EWG and R 2 form a cyclic electron-withdrawing unit), the cyclic unit preferably comprises a C═O, C═S, or a C═N at a first carbon atom, and: a C═O or a C═N attached to a carbon atom at least two carbon atoms away from the first carbon atom; or an O, S, or N as a member of the ring at least two positions away from the first carbon atom; and
[0093] each EDG is an electron-donating group such as —O—, —S—, or
[0094] —R 5 N—, where R 5 is hydrogen or an acyclic (preferably C 1 -C 2 ) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl;
[0095] R 4 is a divalent, non-aromatic-containing bridging group such as —(CH 2 ) n —, dimethylenecyclohexyl (—CH 2 —C 6 H 4 —CH 2 —), —CH 2 CH 2 —O—CH 2 CH 2 —, or other acyclic (preferably C 1 -C 4 , branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyls or heteroalkyls; and
[0096] (1)-(4) refer to the respective double-bonded carbon atoms.
[0097] Examples of particularly preferred structures A of Formula VIII where R 3 is structure D (i.e., so that EWG and R 2 form a cyclic electron-withdrawing unit) include the following:
[0098] where each R 1 is non-aromatic and may individually be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, and each R 2 is non-aromatic and may individually be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group.
[0099] Examples of particularly preferred structures B of Formula VIII where EWG and R 2 form a cyclic electron-withdrawing unit include the following:
[0100] where R 1 is non-aromatic and may individually be hydrogen, acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, and each R 2 is non-aromatic and may individually be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group.
[0101] In another embodiment, a light attenuating compound is attached to a polymer binder (either directly to the backbone or via a linkage unit) via an EWG. A specific example of one such structure is shown in Formula IX.
[0102] where EWG is a non-aromatic electron-withdrawing group such as a carbonyl, cyano, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group, and each R 1 may individually be hydrogen or an alkyl group (and preferably a methyl group).
[0103] One preferred structure of Formula IX wherein the EWG (a carboxyl group) is directly attached to a polymer backbone as shown below.
[0104] In another embodiment, two R 1 substituents on a moiety of the light attenuating compound form a cyclic structure such as those shown in Formulas X and XI.
[0105] where: R 2 is non-aromatic and may individually be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, cyano, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group; and EWG is a non-aromatic electron-withdrawing group such as a carbonyl, cyano, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group.
[0106] where: R 2 is non-aromatic and may individually be hydrogen, an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl, or an electron-withdrawing group such as a carbonyl, imino, cyano, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group; and EWG is a non-aromatic electron-withdrawing group such as a carbonyl, cyano, imino, carboxylic acid, carboxylic ester, carboxamido, carboximido, or sulfonyl group.
[0107] In yet another embodiment, the disclosed Formulas can be joined to one another to form a polymeric structure for use in a photolithographic composition without the need for an additional polymer binder. That is, the polymerized structures would act as the polymer binder as well as the light absorbing compound. The structures of Formulas I-XI can by polymerized in a linear fashion by creating non-conjugated, non-aromatic linkages between two of the functional groups as shown in the table below.
For- mula Linkages Between: I R 1 —R 1 ; R 1 —R 2 ; R 1 -EWG; and R 2 -EWG II R 1 -EDG; R 1 -EWG; R 1 —R 2 ; EDG-EWG; R 2 -EDG; and R 2 -EWG III R 1 —R 1 ; R 1 —R 2 ; R 1 -EWG; and R 2 -EWG IV R 1 —R 1 ; R 1 -EWG; and EWG-EWG V R 1 -EDG; R 1 -EWG; R 1 —R 2 ; EDG-EWG; R 2 -EWG; and R 2 -EWG VI R 1 ′—R 2 ″ and R 1 ′—R 1 ″ VII R 1 ′—R 2 ″; R 1 ′—R 1 ″; R 1 ′-EDG″; R 2 ′-EDG″; and EDG′-EDG″ VIII R 1 ′—R 2 ″; R 1 ′—R 1 ″; R 1 ′-EWG″; R 2 ′-EWG″; and EWG′-EWG″
[0108] Linkage units could be utilized between the structures to form the above-described linkages. Suitable linkage units include a moiety selected from the group consisting of alkyls, acyclic heteroalkyls, non-aromatic cyclic alkyls, and non-aromatic cyclic heteroalkyls.
[0109] As indicated previously, the light attenuating compound can be attached to the polymer binder backbone or to a functional group or linkage unit which is, in turn, attached to the polymer backbone. Structures E and F below illustrate these attachments. In structure E, a 365 nm dienyl dye having an amino electron-donating group is bonded to a polymer binder via a hydroxypropyl linking group. The dye is attached by a carboxylic ester electron-withdrawing group. In structure F, the amino electron-donating group is functionalized with two hydroxyethyl substituents which are reacted with a diisocyanate to form a polyurethane backbone.
[0110] When used in reference to Formulas I-XI, the term “compounds” is intended to refer to the actual compound represented in the particular Formula, as well as all functional olefinic and/or diolefinic moieties thereof. For example, the “compound of structure A of Formula I,” refers to the structure A shown in Formula I above as well as the structure:
[0111] where “M” is a compound to which R′ is bonded. Thus, “compound of structure A of Formula I” would include those moieties where any of the constituents (i.e., any of the R groups or the EWG) are bonded to another compound.
[0112] Also, as used herein, “cyclic” is intended to refer to any group, compound, or moiety which includes a cyclic group as part of its structure. Thus, cyclic would include groups such as methylenecyclohexyl (—CH 2 —C 6 H 5 ) and ethylenecyclohexyl.
[0113] The following table sets forth preferred compounds which fall into the classes described above with respect to Formulas I-XIII.
Class Preferred Sunstituents Acyclic Alkyls methyl, ethyl, propyl, and isopropyl Cyclic Alkyls cyclopentyl and cyclohexyl Acyclic Heteroalkyls methoxyethyl, ethoxyethyl, methoxypropyl, chloroethyl, and 1,1,1-trifluoroethyl Cyclic Heteroalkyls tetrahydrofurfuryl, methylenecyclohexyl (—CH 2 —C 6 H 5 ), and ethylenecyclohexyl EWG's Having —CO—CH 3 , —CO—CH 2 CH 3 , and —CO—CH 2 (CH 3 ) 2 Carbonyl Groups EWG's Having —CO—O—CH 3 , —CO—O—CH 2 CH 3 , and Carboxyl Groups —CO—O—CH 2 —CH(OH)—CH 2 —O— EWG's Having —CO—NH—CH 2 —CH 2 —OH and —CO—NH—CH 2 —CH 2 —O— Carboxamido Groups EWG's Having —SO 2 —CH 3 and —SO 2 CH 2 CH 3 Sulfonyl Groups EDG's Having an H 3 C—O—, H 3 CCH 2 —O—, —CH 2 CH 2 —O—, and R 1 —O—, Alkoxy Group wherein R 1 is non-aromatic and may individually be hydrogen, or an acyclic (preferably C 1 -C 4 branched or unbranched) or cyclic (preferably C 5 -C 6 ) alkyl or heteroalkyl EDG's Having an (H 3 C) 2 N—, (H 3 CCH 2 ) 2 N—, (—O—CH 2 CH 2 ) 2 N—, and R x R y N Group
EXAMPLE
[0114] The following example sets forth preferred methods in accordance with the invention. It is to be understood, however, that this example is provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.
[0115] Poly(glycidyl methacrylate) was reacted with 2,4-hexadienoic acid (a non-aromatic, deep ultraviolet chromophore) at 100-110° C. for 24 hours with a benzyltriethylammonium chloride catalyst to form a solution of the dye-attached binder shown in Scheme A.
Scheme A—2,4-Hexadienoic Acid Attached to Poly(glycidyl methacrylate)
[0116] [0116]
[0117] The resulting polymer binder was combined in solution (with 1-methoxy-2-propanol and ethyl lactate as the solvents) with a glycouril-formaldehyde cross-linking agent and an acid catalyst (p-toluenesulfonic acid) to form a BARC composition. The concentrations of the various compounds utilized in the composition were as follows:
Compounds Parts by Weight a Polymer Solution 14.52 Cross-Linking Agent 0.66 p-toluenesulfonic acid 0.06 1-methoxy-2-propanol 42.38 ethyl lactate 42.38
[0118] The composition was spin coated onto a silicon wafer at 1500 rpm for 60 seconds followed by a hotplate bake at 175° C. for 60 seconds to form a BARC layer with a film optical density at 248 nm of 4.83/micron. The coating was then plasma etched in a commercial wafer etching tool using a mixture of HBr and O 2 as the etchant gas. The etch rate of the coating was 5815 Å/minute.
[0119] For comparison purposes, the etch rate of a BARC composition (DUV-42 for use in 248 nm photolithographic processes, available from Brewer Science, Inc., Rolla, Mo.) was determined. The binder in DUV-42 is a copolymer of glycidyl methacrylate and 2-hydroxypropyl methacrylate in which the glycidyl groups have been reacted with 9-anthracenecarboxylic acid (9-ACA) to form a dye-attached binder with high light absorbency at 248 nm. The DUV-42 was applied to a silicon wafer and processed following the procedures set forth above with respect to the inventive composition. The etch rate of the DUV-42 was 3218 Å/minute. Thus, the composition utilizing a light attenuating compound according to the invention etched 1.8 times faster than the prior art product. The comparatively low plasma etch rate of the DUV-42 was a result of the high aromatic ring content of the 9-ACA. | An improved light attenuating compound for use in the production of microdevices is provided. Broadly, the light attenuating compound is non-aromatic and can be directly incorporated (either physically or chemically) into photolithographic compositions such as bottom anti-reflective coatings (BARC) and contact or via hole fill materials. The preferred non-aromatic compounds of the invention are conjugated aliphatic and alicyclic compounds which greatly enhance the plasma etch rate of the composition. Furthermore, the light attenuating compounds are useful for absorbing light at shorter wavelengths. In one embodiment, the inventive compounds can be polymerized so as to serve as both the polymer binder of the composition as well as the light absorbing constituent. | 8 |
BACKGROUND
[0001] The invention relates to voltage sensors, and more particularly relates to voltage sensors that measure AC mains voltage and output to a circuit that is safe for an operator to touch (SELV circuit). In one or more specific applications, the invention relates to highly accurate, inexpensive, and physically small voltage sensors for use in devices that are UL 60950-1 compliant, and to UL 60950-1 compliant devices that use such sensors. The following description focuses upon use of the invention in a specific context, namely a UL 60950-1 compliant power distribution unit (“PDU”) but the invention is not limited to PDU applications and can be used in other applications where UL 60950-1 compliance or other safety standards are necessary or commercially advantageous.
[0002] The UL 60950-1 standard establishes requirements that reduce risks to persons who operate and service information technology equipment (“IT equipment”). Examples of IT equipment are data and text processing machines, data network equipment, such as routers, telecom switches, servers, modems, and PDUs (discussed in more detail below), but IT equipment is intended to be interpreted in the broadest sense and is not limited to these specifically enumerated devices or to PDUs in particular.
[0003] IT equipment typically derives power from the AC mains supply (“primary”) and contains input/output interfaces (“I/O”) that interconnect with other IT equipment. UL 60950-1 requires user accessible I/O to be safe to touch. A safe to touch circuit is defined by UL 60950-1 as a “secondary extra low voltage” circuit (“SELV”). According to UL 60950-1, a SELV circuit must satisfy these requirements: (a) has no direct connection to a primary and derives its power from a transformer, converter or equivalent isolation device, (b) is limited to 42.4 V peak, and (c) insures that requirements (a) and (b) are met under normal operating conditions and single fault conditions.
[0004] IT equipment rooms (also known as data centers) utilize hundreds or even thousands of units of IT equipment. Each piece of IT equipment receives primary power by plugging into an outlet of a power distribution unit (“PDU”). A PDU is also a piece of IT equipment and it typically includes: (a) a high power inlet from which it receives power (typically from a panel board), (b) multiple lower power outlets, and (optionally) (c) circuit breakers or fuses to protect the outlets from over current conditions (short circuits, etc.).
[0005] PDUs designed for IT equipment rooms advantageously perform functions additional to power distribution. For example, intelligent PDUs can report certain status information over a communication and/or input/output interface, including: (a) the voltage being supplied to the PDU's inlet, (b) how much power (power=voltage times current) is flowing in the inlet and each outlet, and (c) the trip state (whether voltage is present) of each circuit breaker. Since gathering the above status information relies on sensing voltage, an IT equipment room with thousands of units of IT equipment will therefore require thousands of such voltage sensors. It will therefore be evident that requirements for such voltage sensors should include: (a) the ability to measure a primary voltage and output to a SELV circuit, (b) highly accurate output, (c) low cost, and (d) small size.
[0006] Conventionally, voltage sensors able to measure voltage in a primary circuit and output the measurement to a SELV circuit have been built using transformers, opto-coupler devices, Hall effect devices, etc. These devices are used in order to meet the primary to secondary isolation requirements of a SELV circuit (which are, again, established by the particular standard at issue, such as UL 60950-1). However, these devices do not make highly accurate sensors, and are expensive and large in size.
[0007] Reference is made to FIGS. 1 and 2 , which schematically illustrate a safety compliant power distribution unit (PDU), including conventional voltage sensors to achieve primary to secondary isolation. The system includes a power distribution unit (PDU) ( 2 ), which receives primary AC mains power from an inlet ( 1 ). A measurement of the voltage and power at the inlet ( 1 ) is made using one or more voltage sensors ( 5 ). Primary voltage from the inlet ( 1 ) is wired to the inputs of one or more circuit breakers ( 3 ) (if any), or other over-current protectors, such as fuses (not shown). The purpose of each circuit breaker ( 3 ) is to limit the electrical current flowing in the associated outlet receptacles ( 4 ) by switching off voltage (interrupting the current path) when the current flowing through the given circuit breaker ( 3 ) exceeds its rating. The on/off (“trip”) state of a given one or more of the circuit breakers ( 3 ) can be detected using one or more voltage sensors ( 6 ) to sense presence of primary voltage at the output of the circuit breaker ( 6 ). Primary voltage from the output of each circuit breaker ( 6 ) is wired to one or more outlet receptacles ( 4 ). A unit of IT equipment ( 8 ) can receive power from the PDU ( 2 ) by connecting an inlet plug ( 9 ) of the IT equipment ( 8 ) into one of the outlet receptacles ( 4 ) of the PDU ( 2 ). A measurement of the voltage at the outlet receptacle ( 4 ), and power drawn by the IT equipment ( 8 ), is made using one or more voltage sensors.
[0008] Conventional voltage sensors that may be used to perform the voltage and power measurements in FIG. 1 are shown in FIG. 2 . The voltage and power of the inlet ( 1 ) is shown being measured using a SELV circuit ( 8 ) that uses a step down transformer voltage sensor ( 6 ) and a current sensor ( 7 ) to compute power using the well known electric power formula (power=voltage times current). The step-down transformer ( 6 ) meets the isolation requirements of a SELV circuit by using a magnetic field to isolate its input connection to the primary side, lines ( 2 a and 3 ) from its output ( 6 a ) connection to the SELV circuit ( 8 ). The voltage requirements of a SELV circuit are met by using a winding ratio that reduces its output ( 6 a ) voltage to less than 42.4V peak. In addition, a fuse ( 9 a ) is usually included to prevent a short circuit in the event of a fault in the step down transformer voltage sensor ( 6 ).
[0009] Disadvantages of the step down transformer ( 6 ) include its large size, high cost and significant inaccuracies. The step down transformer ( 6 ) is large and expensive because of a number of turns of magnet wire required to handle the high voltage and low frequency of the primary AC voltage. The step down transformer ( 6 ) is inaccurate because its magnetic inductive coupling results in output amplitude and phase shift variance between different transformers of the same make and model number.
[0010] The on/off state of each circuit breaker ( 3 ) is monitored with a separate SELV circuit ( 12 ). The SELV circuit ( 12 ) uses an optical isolator ( 10 ) as a voltage sensor and this meets the isolation requirements of a SELV circuit by using light to isolate its input ( 10 a ) connection to the primary side lines ( 2 b and 3 ) from its output ( 10 b ) connection to the secondary side SELV circuit ( 12 ). The light emitting diode (“LED”) ( 10 a ) of the optical isolator ( 10 ) is wired in series with a current limit resistor ( 11 ) and these two devices are then wired across the primary output ( 2 b ) of the circuit breaker ( 10 ) and the primary line ( 3 ). When the circuit breaker ( 10 ) is closed and in the normal operating state, the LED ( 10 a ) turns on and off once every primary AC voltage cycle. When the LED ( 10 a ) is on, it emits photons which turn on the transistor ( 10 b ) of the optical isolator ( 10 ). When the circuit breaker ( 10 ) is open (“tripped”), no LED ( 10 a ) current flows and the transistor ( 10 b ) remains turned off. The SELV circuit ( 12 ) detects whether or not the transistor ( 10 b ) is turning on and off as an indication of the trip state of the circuit breaker ( 10 ).
[0011] Among the disadvantages of the optical isolator ( 10 ) is the relatively large power required to turn on its LED ( 10 a ). For example, an LED requiring 1 mA of current would require 0.250 watts when used to measure a 250V primary AC mains line. Optical isolators are also inherently inaccurate, especially over temperature, and are relatively unreliable as compared with, for example, a simple resistor network.
[0012] The voltage and power of each outlet receptacle ( 5 ) in FIG. 2 is shown using a primary powered measurement circuit ( 13 ) that uses a resistor voltage sensor ( 12 ) and current sensor ( 7 ). However, because the resistor voltage sensor ( 12 ) is not isolated from the primary side AC power ( 2 b ), the primary circuit ( 13 ) requires isolation circuitry ( 14 ), such as an optical isolator or other type of circuit, to connect it to the SELV circuitry ( 15 ).
[0013] The disadvantages of the primary powered resistive sensor measurement circuit ( 13 ) combined with the isolation circuitry ( 14 ) are, again, its cost, complexity, accuracy and/or reliability issues.
[0014] Although resistor sensors are known to exhibit inherent linearity, high accuracy, low cost and small size, such sensors have not been used to provide sensed voltages across isolation boundaries in circuits requiring isolation from primary to secondary (such as SELV circuits). Indeed, the accepted wisdom in the circuit design arts is exactly opposite; namely, to avoid resistive sensing networks in such applications. Such accepted wisdom has been developed over years and years of ingrained group-thinking (which has been passed from master to apprentice) that the use of resistive networks would fail to meet safety/isolation standards, such as those required by UL 60950-1. Consequently, there are no known circuits in the prior art employing resistive networks to provide sensed voltages across isolation boundaries. Moreover, owing to the accepted wisdom in this art area, skilled artisans are not motivated to use resistive networks in such applications. Thus, a long felt, but unsatisfied, need has developed in this area of circuit design, which has been simply accepted by those skilled in the art.
SUMMARY OF THE INVENTION
[0015] Again, in one or more specific embodiments, the invention may provide a highly accurate, inexpensive, and physically small voltage sensor to provide sensed voltages across an isolation boundary in a circuit requiring isolation from primary to secondary (such as set forth in UL 60950-1). It bears repeating, however, that it is contemplated that the invention may be embodied in any number of circuits, systems, devices, etc. where UL 60950-1 compliance or other safety standards are necessary or desired.
[0016] One or more aspects of the invention proceed from the entirely unexpected discovery that a voltage sensor, if properly designed using a plurality of resistors configured as a voltage divider, can satisfy known safety/isolation requirements (such as the UL 60950-1 SELV requirements). In this regard, it has been discovered that a voltage sensor designed using a plurality of resistors in a particular way can satisfy at least the following additional safety/isolation requirements:
1. The voltage sensor resistors may connect between one or more nodes on the primary side and one or more nodes of the secondary side (e.g., the SELV) provided that minimum clearance and creepage spacing requirements are met (for example the requirements set forth in UL 60950-1 section 1.5.7). This requirement may be satisfied, for example, by constructing the voltage sensor resistors on a printed circuit board where the distance between components meets the desired clearance and spacing values. 2. Under normal operating conditions, or when any single component (in this case resistors) in the sensor fails due to an open or short circuit, the current flow from the primary side circuit to the secondary side circuit (e.g., SELV circuit) must be less than a specified threshold level (e.g., 700 microamperes peak as specified in UL 60950-1 sections 1.5.7 and 2.4). This requirement may be satisfied by using a plurality of resistors wired in series, each of sufficiently high resistance such that if any one of the resistors is shorted or opened, the resulting current flow from the primary side circuit to the secondary side circuit is less than the threshold level, e.g., 700 microamperes peak. 3. The resistors must not break down or short when subjected to a high voltage applied to the highest potential source in the primary side circuit (the so-called hipot). By way of example, a hipot is specified in UL 60950-1 section 5.2. This requirement may be satisfied by choosing resistors with sufficiently high working voltages. 4. The voltage one any node of the secondary side circuit (e.g., the SELV circuit) may not exceed a particular threshold level (e.g., 42.4V peak as specified in UL 60950-1 section 2.2). This requirement may be met by choosing the ratio-metric values of the resistors in the voltage divider to limit the SELV voltage to the threshold level, e.g., 42.4V peak.
[0021] In accordance with one or more aspects of the present invention, an apparatus includes: a primary side circuit including one or more voltage nodes; and a monitoring circuit operating to monitor one or more parameters of the primary side circuit, and including at least one sensing circuit and at least one processing circuit within a secondary side circuit. The sensing circuit may include a resistor network having an input for receiving a first sensed voltage from a first of the voltage nodes of the primary side circuit, traversing an isolation boundary between the primary side circuit and the secondary side circuit while adhering to a safety specification, which includes a primary-secondary isolation requirement, and having an output for providing a first modified sensed voltage to the processing circuit.
[0022] The resistor network preferably includes: a plurality of series-coupled resistors, which are connected at one end to the first voltage node of the primary side circuit, and are connected at an opposite end to a junction node; and a shunt resistance coupled from the junction node to a reference potential. The output providing the first modified sensed voltage to the processing circuit is at least one of taken from, and derived from, a voltage at the junction node.
[0023] In accordance with one or more embodiments, the first voltage node of the primary side circuit exhibits a single ended voltage potential with respect to the reference potential; and the output providing the first modified sensed voltage to the processing circuit is a single ended voltage taken from the junction node with respect to the reference potential.
[0024] In accordance with one or more further embodiments, the first voltage node of the primary side circuit exhibits a single ended alternating current (AC) voltage potential with respect to the reference potential; the apparatus further includes a switching circuit including an input terminal coupled to the junction node and an output terminal, which pulses in response to the AC potential at the input terminal; and the output providing the first modified sensed voltage to the processing circuit is a single ended pulsed voltage taken from the output terminal of the switching circuit with respect to the reference potential. The single ended pulsed voltage indicates the presence or absence of the AC voltage potential of the primary side circuit.
[0025] The switching circuit may include a switching transistor having an input terminal and two output terminals; the input terminal of the switching transistor is the input terminal of the switching circuit; one of the output terminals of the switching transistor is held at a bias voltage potential; the single ended pulsed voltage is taken from the other of the output terminals of the switching transistor with respect to the reference potential. For example, the switching transistor may be a bipolar junction transistor, having a base as an input terminal, an emitter coupled to the reference potential and a collector from which the single ended pulsed voltage is taken.
[0026] In accordance with one or more further embodiments of the present invention: first and second voltage nodes of the primary side circuit produce a differential voltage; the plurality of series-coupled resistors includes first and second pluralities of series-coupled resistors; the first plurality of series-coupled resistors are connected at one end to the first voltage node of the primary side circuit, and are connected at an opposite end to a first junction node; and the second plurality of series-coupled resistors are connected at one end to the second voltage node of the primary side circuit, and are connected at an opposite end to a second junction node.
[0027] In accordance with some aspects, the shunt resistance may include first and second resistances, the first resistance coupled from the first junction node to the reference potential, and the second resistance coupled from the second junction node to the reference potential; and the output providing the first modified sensed voltage to the processing circuit may be taken as a differential output between the first and second junction nodes.
[0028] In accordance with alternative or additional aspects, the apparatus further comprises a differential to single ended conversion circuit having first and second input terminals and an output terminal; the shunt resistance includes first and second resistances; the first resistance is coupled from the first junction node to a first potential, and the first junction node is coupled to the first input terminal of the differential to single ended conversion circuit; the second resistance is coupled from the second junction node to a second potential, and the second junction node is coupled to the second input terminal of the differential to single ended conversion circuit; and the output providing the first modified sensed voltage to the processing circuit is taken as a single ended output at the output terminal of the differential to single ended conversion circuit with respect to the reference potential.
[0029] The differential to single ended conversion circuit may include an operational amplifier having first and second input terminals and an output terminal, which are the first, second and output terminals of the differential to single ended conversion circuit, respectively; the first potential is at a voltage potential above the reference potential; the second resistance is coupled from the second junction node to the output terminal of the operational amplifier; and the single ended output is taken at the output of the operational amplifier with respect to the reference potential.
[0030] In accordance with one or more further aspects of the present invention, the one or more voltage nodes of the primary side circuit are coupled to a source of power and the monitoring circuit operates to monitor one or more parameters of the source of power.
[0031] In accordance with one or more further aspects of the present invention, the sensing circuit does not employ any optical devices, transformer devices, and/or Hall effect devices in traversing the boundary from the first sensed voltage to the first modified sensed voltage.
[0032] Other aspects, features, and advantages of the present invention will be apparent to one skilled in the art from the description herein taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] Exemplary and non-limiting embodiments of the invention are illustrated in the figures. The drawings may not be to scale, various details may be enlarged or reduced for clarity, and the illustrate values of any electrical components are merely exemplary and not limiting.
[0034] FIG. 1 schematically illustrates a safety compliant power distribution unit (PDU) consisting of an inlet, outlets, circuit breakers and voltage sensors for measuring power and detecting circuit breaker open/close state.
[0035] FIG. 2 schematically illustrates conventional voltage sensors that use transformers and opto-isolators in order to achieve primary to secondary isolation.
[0036] FIG. 3 schematically illustrates a preferred embodiment of the invention for a voltage sensor with a single ended primary side sensed input and a single ended output for connection to a secondary side circuit.
[0037] FIG. 4 schematically illustrates a preferred embodiment of the invention for a voltage sensor with a differential primary side sensed input and a differential output for connection to a secondary side circuit.
[0038] FIG. 5 schematically illustrates a preferred embodiment of the invention for a voltage sensor with a differential primary side sensed input and single ended output for connection to a secondary side circuit.
[0039] FIG. 6 schematically illustrates a preferred embodiment of the invention for a voltage sensor to sense the presence or absence of AC voltage via a single ended sensed input on a primary side and a pulse wave output for connection to a secondary side circuit.
[0040] FIG. 7 is a flow chart showing the operation of the embodiment of FIG. 6 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0041] Although one or more embodiments of the invention may be designed for use in a PDU intended for IT equipment applications, and is here illustrated as used in such a PDU, this is not required. Various aspects of the invention are suitable for use in any application requiring an inexpensive, accurate, small and low power consumption voltage (or current) sensor that measures the voltage or current of a primary side source and outputs the measured value(s) across an isolation boundary to a secondary side circuit, such as a UL 60950-1 compliant SELV circuit.
[0042] FIG. 3 illustrates a preferred embodiment of the invention in a system 100 , that includes a voltage sensor that performs a single ended measurement between a primary side AC main line ( 1 ) and ground ( 107 ) and outputs a scaled down AC voltage single ended SELV output ( 108 ). A single ended input, single ended output sensor is useful when measuring a primary 4-wire 3-phase AC power line ( 1 ), which includes lines ( 1 a , 1 b , 1 c , 1 d ) using a SELV circuit ( 109 ) that incorporates single ended analog to digital converters. By way of example, the Analog Devices ADE7878 Energy Metering IC may be used as the SELV 109 . Three identical voltage sensors ( 100 a , 100 b , 100 c ) may be used, and thus only a detailed description of voltage sensor 100 a is described in the following paragraphs.
[0043] Voltage sensor ( 100 a ) is used in SELV circuits that measure voltage and power and eliminates the need for the conventional voltage sensors, such as step down transformers ( 6 ) and other isolated primary circuits shown in FIG. 2 . Voltage sensor 100 a has the advantages of being smaller, less costly and more accurate than conventional voltage sensors used to provide measured voltage to SELV circuits. The components of the voltage sensor 100 a may include small surface mount resistors and (optionally) one small surface mount capacitor. Thus, the total cost for the voltage sensor ( 100 a ) may be less than about $0.10 in parts. The sensor is extremely accurate and exhibits precise amplitude and phase response.
[0044] Voltage sensor 100 a is a voltage divider including a series resistance network ( 103 ), shunt resistance ( 104 ) (only one resistor required in this embodiment), and an optional shunt capacitance, which may be implemented using a single capacitor ( 105 ). The shunt capacitor ( 105 ) is only required when the SELV circuit ( 109 ) requires its input to be frequency limited by a low pass filter.
[0045] Series resistance ( 103 ) is made up of a plurality of resistors. In this embodiment, which is intended to meet the requirements of UL 60950-1 (and the specific line-ground voltage characteristics of the source), seven identical 1.5 megohm, 800 working volt resistors are employed to implement the series resistance ( 103 ). However, it is understood that the exact number of resistors, their resistance values, and voltage ratings may vary providing they satisfy the requirements of the given safety standard, in this case UL 60950-1. Series resistance ( 103 ) connects to the primary side on one end ( 1 a ), and connects to the SELV ( 109 ) of the secondary side on the other end ( 108 ).
[0046] A resistance connecting the primary side to the SELV ( 109 ) is permitted in UL 60950-1 providing it meets certain requirements. Series resistance ( 103 ) satisfies UL 60950-1 as follows: (1) the component resistors of the series resistance ( 103 ) are mounted on a printed circuit board (not shown) where the distance between components meets UL 60950-1 clearance and spacing values; (2) when any one of the component resistors of the series resistance ( 103 ) fails due to an open or short circuit, the current flow from the primary side ( 1 a ) to the output ( 108 ), which is input to the SELV circuit ( 109 ) is less than 700 microamperes peak; and (3) the breakdown voltage of series resistance ( 103 ) is 5600V—the sum of the working voltages of the seven component resistors wired in series. This breakdown voltage satisfies the electric strength test (hipot) requirement of UL 60950-1 section 5.2.
[0047] Shunt resistor ( 104 ) reduces the primary voltage so that it does not exceed the 42.4V peak maximum specified in UL 60950-1 section 2.2. The voltage reduction uses the well known voltage divider formula: ratio=shunt/(shunt+series). A preferred value of 7.87 k for resistor ( 104 ) results in a ratio of 0.000749, which reduces a 250V AC primary voltage ( 1 a ) down to a 0.187 volt AC signal on output ( 108 ), which is suitable for the Analog Devices ADE 7878 Energy Metering IC, which as discussed above may be used to implement the SELV circuit ( 109 ).
[0048] The shunt capacitor ( 105 ) implements an inexpensive first order low pass anti-alias filter for the SELV circuit ( 109 ), which requires its voltage inputs to be frequency band limited. The −3 dB cut off frequency of the low pass filter occurs when the magnitude of the capacitor's impendence equals the resistance of the shunt resistor ( 104 ) using the well known capacitor impedance formula: Z=1/(2π*frequency*capacitance). Thus, for the 7.87 k shunt resistance ( 104 ) and a 4 nanofarad capacitance ( 105 ), the −3 dB cut off frequency is approximately 5 kHz, which is suitable for use with the Analog Devices ADE 7878 Energy Metering IC ( 109 ).
[0049] FIG. 4 illustrates a preferred embodiment of the invention as implemented in a system ( 200 ) including a voltage sensor that performs a differential measurement across two primary side AC mains lines ( 5 a , 5 b ) and outputs a scaled down differential AC voltage output ( 6 a , 6 b ) for connection to a secondary side SELV circuit ( 204 ). A differential output sensor is useful with SELV circuits ( 204 ) that incorporate differential input analog to digital converters. For example, the SELV circuit ( 204 ) may be implemented using the Analog Devices ADE 7763 energy meter integrated circuit. This type of sensor is used in SELV circuits that measure voltage and power and avoids the need for conventional voltage sensors, such as the step down transformers and isolated primary circuits shown in FIG. 2 .
[0050] This voltage sensor has the advantages of being smaller, less costly and more accurate than conventional voltage sensors used in such applications where isolation is required or desired. The components of the system 200 preferably include a plurality of small, surface mount resistors ( 201 a , 201 b , 202 a , and 202 b ) and (optionally) a plurality of small, surface mount capacitors ( 203 a , 203 b ). The total part cost for components shown is less than about $0.20. The voltage sensor is extremely accurate and exhibits precise amplitude and phase response.
[0051] The voltage sensor includes two identical voltage dividers, where each divider contains a series resistance ( 201 a and 201 b ), a shunt resistance ( 202 a and 202 b ), and a shunt capacitance ( 203 a and 203 b ). The shunt capacitance, which in this case is implemented as a single capacitor ( 203 a and 203 b ) in each voltage divider, are only required when the SELV circuit ( 204 ) requires its input to be frequency limited by a low pass filter.
[0052] Series resistors ( 201 a and 201 b ) are each made up of a plurality of series-coupled resistors, for example seven identical 1.5 megohm, 800 working volt resistors. Again, although the exact number of resistors, their values and voltage ratings may vary, the combination should satisfy the requirements of the particular safety standard at issue, in this example, UL 60950-1.
[0053] Each series resistance ( 201 a and 201 b ) satisfies UL 60950-1 as follows: (1) the component resistors of each series resistance are mounted on a printed circuit board (not shown) where the distance between components meets UL 60950-1 clearance and spacing values; (2) when any one of the component resistors of either series resistance ( 201 a and 201 b ) fails due to an open or short circuit, the current flow from the primary side ( 205 a and 205 b ) to the outputs ( 206 a , 206 b ), which are input to the SELV circuit ( 204 ) is less than 700 microamperes peak; and (3) the breakdown voltage of each series resistance ( 201 a , 201 b ) is 5600V—the sum of the working voltages of the series-coupled component resistors in each resistance ( 201 a , 201 b ). This breakdown voltage satisfies the electric strength test (hipot) requirement of UL 60950-1 section 5.2.
[0054] Shunt resistors ( 202 a and 202 b ) reduce the primary voltage so that it does not exceed the 42.4V peak maximum specified in UL 60950-1 section 2.2. The voltage reduction uses the well known voltage divider formula: ratio=shunt/(shunt+series). The preferred values of 7.87 k for resistors ( 202 a , 202 b ) results in a ratio of 0.000749 which will reduce a 250V AC primary voltage ( 205 a and 205 b ) down to a 0.187 volt AC signal on either of lines ( 206 a and 206 b ), which is suitable for the Analog Devices ADE 7763 Energy Metering IC SELV circuit ( 204 ).
[0055] The shunt capacitors ( 203 a and 203 b ) implement an inexpensive first order low pass anti-alias filter for SELV circuits that require their inputs to be frequency band limited. The −3 dB cut off frequency of the low pass filter occurs when the impendence magnitude of the capacitor equals the resistance of the shunt resistor ( 202 a or 202 b ) using the well known impedance formula for capacitors: f=1/(2π*frequency*capacitance). For the 7.87 k shunt resistance ( 202 a and 202 b ) and a 4 nanoFarad capacitance ( 203 a and 203 b ), the −3 dB cut off frequency is approximately 5 kHz which is suitable for use with the Analog Devices ADE 7763 Energy Metering IC ( 204 ).
[0056] FIG. 5 illustrates a preferred embodiment of the invention as implemented in a system 300 including a voltage sensor that performs a differential measurement across two primary side AC mains lines ( 305 a , 305 b ) and outputs a scaled down AC voltage single ended output on line ( 306 ) for input to a SELVE circuit ( 304 ). A single ended output sensor is useful with SELV circuits ( 304 ) that incorporate single ended input analog to digital converters. By way of example, the SELV circuit 304 may be implemented using a general purpose microprocessor, like the ST Microelectronics STM32 microcontroller integrated circuit.
[0057] This type of sensor is used in SELV circuits that measure voltage and power, and avoids the need for conventional voltage sensors, such as step down transformers and isolated primary circuits shown in FIG. 2 . This sensor has the advantages of being smaller, less costly and more accurate than conventional voltage sensors used to provide measured voltages across isolation boundaries. The components of the voltage sensor includes a plurality small, surface mount resistors ( 301 a , 301 b , 302 a , 302 b ), a general purpose operational amplifier ( 307 ), and (optionally) a plurality of small, surface mount capacitors ( 303 a , 303 b ). The total parts cost for these components is less than about $0.45. The sensor is extremely accurate and exhibits precise amplitude and phase response.
[0058] The voltage sensor preferably includes two identical voltage dividers where each divider contains a series resistance ( 301 a and 301 b ), a shunt resistance ( 302 a and 302 b ), and an (optional) shunt capacitance ( 303 a and 303 b ).
[0059] Series resistances ( 301 a and 301 b ) are each made up of a plurality of series-coupled resistors. By way of example, each series resistance ( 301 a and 301 b ) may include seven identical 1.5 megohm, 800 working volt resistors. Again, although the exact number of resistors, their values and voltage ratings may vary, they are intended to satisfy the requirements of the particular safety standard at issue, in this case UL 60950-1. Series resistances ( 301 a and 301 b ) each satisfy UL 60950-1 as follows: (1) the component resistors of each series resistance are mounted on a printed circuit board (not shown) where the distance between components meets UL 60950-1 clearance and spacing values; (2) when any one of the component resistors of either series resistance ( 301 a and 301 b ) fails due to an open or short circuit, the current flow from the primary side ( 305 a and 305 b ) to the output ( 306 ), which is input to the SELV circuit ( 304 ) is less than 700 microamperes peak; and (3) the breakdown voltage of each series resistance ( 301 a , 301 b ) is 5600V—the sum of the working voltages of the series-coupled component resistors in each resistance ( 301 a , 301 b ). This breakdown voltage satisfies the electric strength test (hipot) requirement of UL 60950-1 section 5.2.
[0060] Shunt resistances ( 302 a and 302 b ), which are implemented in this example by respective, single resistors, reduce the primary voltage so that it does not exceed the 42.4V peak maximum specified in UL 60950-1 section 2.2. The shunt capacitance ( 303 a and 303 b ), which are implemented in this example by respective, single capacitors, result in an inexpensive first order low pass anti-alias filter for SELV circuits that require their inputs to be frequency band limited. The −3 dB cut off frequency of the low pass filter occurs when the impendence of a given capacitor ( 303 a , 303 b ) equals that of the respective shunt resistor ( 302 a or 302 b ) using the well known impedance formula for capacitors: Z=1/(2π*frequency*capacitance). For a 47 k shunt resistance for each resistor ( 302 a and 302 b ), and 680 picofarad capacitance for each capacitor ( 303 a and 303 b ), the −3 dB cut off frequency is approximately 5 kHz, which is suitable for use with the STM32 MCU analog to digital converter ( 304 ).
[0061] The operational amplifier ( 307 ) incorporates the two voltage dividers into a differential amplifier topology. Since the values of the series resistances ( 301 a , 301 b ) are identical and the values of the shunt resistances ( 302 a , 302 b ) are identical, the output of the operational amplifier ( 307 ) adheres to the well known differential operational amplifier gain formula: output=input*shunt/(shunt+series). For preferred values of 1.5 megohm for each resistor of resistances ( 301 a , 301 b ), and 47 k for each resistance ( 302 a , 302 b ), the ratio equals 0.0045, which will reduce a 250V AC primary voltage differential across lines ( 305 a , 305 b ) down to a 1.1 volt AC signal on line ( 306 ), which is suitable for an STM32 microcontroller single ended SELV circuit ( 304 ).
[0062] FIG. 6 illustrates a preferred embodiment of the invention implemented in a system 400 including a voltage sensor that senses the presence or absence of AC voltage by performing a single ended measurement between a primary side AC main line ( 407 ) and ground ( 408 ) and produces a pulse wave output ( 404 ) for input to a secondary side circuit, such as a SELV circuit 405 , when the AC voltage is above a prescribed amplitude threshold. This type of voltage sensor is used in SELV circuits that detect the presence or absence of primary AC voltage, such as blown fuses, tripped circuit breakers or any other type of on/off switched AC voltage.
[0063] This voltage sensor of the system 400 has the advantages of being smaller, less costly and using less power than conventional voltage sensors, such as the optical isolator ( 10 ) shown in FIG. 2 . The components of the system 400 include a plurality of small, surface mount resistors ( 401 , 402 ), and one or more transistors ( 403 ), in this example, one transistor. The total cost for the voltage sensor is less than about $0.10. The sensor draws approximately 5 milliWatts of power from the primary AC power line, which is much less than the 230 milliWatts typically required for the optical isolator ( 10 ).
[0064] The voltage sensor includes a voltage divider, comprising a series resistance ( 401 ) and shunt resistance ( 402 ). The series resistance ( 401 ) is preferably made up of a plurality of series-coupled resistors, such as seven identical 1.5 megohm, 800 working volt resistors. Again, although the exact number of resistors, their values and voltage ratings may vary from application to application, the result is intended to satisfy the requirements of applicable safety standard, such as the UL 60950-1. The series resistance ( 401 ) connects to the primary side on one end ( 407 ), and to the secondary side on the other end ( 410 ), which is coupled to the SELV circuit ( 405 ). A resistive network connecting a primary side to a secondary side SELV circuit, across an isolation boundary, is permitted in UL 60950-1, providing it meets certain requirements. The resistance ( 401 ) satisfies UL 60950-1 as follows: (1) the component resistors of the series resistance ( 401 ) are mounted on a printed circuit board (not shown) where the distance between components meets UL 60950-1 clearance and spacing values; (2) when any one of the component resistors of the series resistance ( 401 ) fails due to an open or short circuit, the current flow from the primary side ( 407 ) to the output ( 404 ), which is input to the SELV circuit ( 405 ) is less than 700 microamperes peak; and (3) the breakdown voltage of series resistance ( 401 ) is 5600V—the sum of the working voltages of the seven component resistors wired in series.
[0065] Shunt resistance ( 402 ), which in this case is implemented with a single resistor, reduces the primary voltage so that it does not exceed the 42.4V peak maximum specified in UL 60950-1 section 2.2. The voltage reduction uses the well known voltage divider formula: ratio=shunt/(shunt+series). For preferred values of 1.5 megohm for each resistor of series resistance ( 401 ), and 100 k for resistance ( 402 ), the ratio equals 0.0095, which will reduce a 250V AC primary voltage ( 407 ) down to a 2.38 volt AC signal on node ( 410 ).
[0066] The base of bipolar transistor ( 403 ) is wired to the voltage divider output ( 410 ), and the bipolar transistor ( 403 ) turns on when the voltage divider output is greater than about 0.6 volts. The ratio of the series and shunt resistances ( 401 , 402 ) is chosen such that any primary AC voltage ( 407 ) greater than about 70 volts will produce an output voltage ( 410 ) greater than the 0.6 volts required to turn on the transistor ( 403 ). When the circuit breaker ( 409 ) is closed and in the normal operating state, the transistor ( 403 ) turns on and off once every primary AC voltage cycle. When the circuit breaker ( 409 ) is open (“tripped”), no primary AC voltage is present at its output ( 407 ) and the bipolar transistor ( 403 ) remains turned off.
[0067] The output of the transistor ( 403 ) is connected to a general purpose input/output (GPIO) pin ( 406 ) of a microprocessor, such as an ST Microsystems STM32, which is suitable to implement the SELV ( 405 ). The general purpose microprocessor is programmed with an algorithm to detect the presence or absence of a pulse wave ( 404 ) on the GPIO input pin ( 406 ). Presence of the pulse wave ( 404 ) is interpreted as circuit breaker closed. Absence of the pulse wave ( 404 ) is interpreted as circuit breaker open (“tripped”).
[0068] A preferred microprocessor algorithm to determine whether the circuit breaker ( 409 ) in FIG. 6 is open or closed is shown as a flowchart in FIG. 7 . The programming steps in the algorithm are carried out over a measurement period, e.g., about one second long, and immediately repeated once a measurement has been concluded. In first step 101 , an accumulator register and a counter register are set to zero. The algorithm then pauses for 100 microSeconds in step 110 . The algorithm then checks the logic state of the GPIO pin in step 120 . If the GPIO pin is a logical “0”, which indicates the presence of a pulse wave, the accumulator is incremented in step 130 . If the GPIO pin is a logical “1” which indicates the absence of a pulse wave, the accumulator is not incremented. The algorithm then increments the counter (step 140 ) and the value of the counter is checked in step 150 . If the counter is less than 10,000, the algorithm repeats from step 110 . If the counter is equal to 10,000 it indicates that 10,000 checks of the GPIO pin have been performed over a one second period and the algorithm proceeds to check the value of the accumulator in step 160 . If the value of the accumulator is greater than 1,000, it indicates the presence of a pulse wave on the GPIO pin with a duty cycle of at least 10 percent and the algorithm outputs a “circuit breaker closed” indication in step 170 . If the value of the accumulator is less than 1,000, it indicates absence of a pulse wave of the GPIO pin and the algorithm outputs a “circuit breaker open” indication in step 180 .
[0069] The algorithm shown in FIG. 7 is robust and immune to noise present on the primary AC voltage because it uses a decision algorithm based on 10,000 measurements over a one second time period.
[0070] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | Methods and apparatus provide for a primary side circuit including one or more voltage nodes; and a monitoring circuit operating to monitor one or more parameters of the primary side circuit, and including at least one sensing circuit and at least one processing circuit within a secondary side circuit, where the sensing circuit includes a resistor network having an input for receiving a first sensed voltage from a first of the voltage nodes of the primary side circuit, traversing an isolation boundary between the primary side circuit and the secondary side circuit while adhering to a safety specification, which includes a primary-secondary isolation requirement, and having an output for providing a first modified sensed voltage to the processing circuit. | 6 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates generally to a circularly polarized beam shaping antenna, and more particularly, to a device for shaping a beam of radiation to create a predetermined radiation pattern by physical rotation of circularly polarized radiator elements on a ground plane of the antenna.
2. Discussion Of The Related Art
In order to avoid interference of one radio system upon another, and to control the area where electromagnetic energy from these systems are radiated, transmitting antennas are known which direct electromagnetic energy in a predetermined radiation pattern. The shape of the radiation pattern is generally dependent on the type of antenna used and the beam shaping technique employed. Currently, there are several different antennas and beam shaping techniques known to shape the radiation pattern, including: (1) aperture shaping techniques; (2) beam shaping with a shaped surface reflector antenna; (3) array fed parabolic reflector antennas; and (4) microstrip reflectarrays.
In the aperture shaping technique, the aperture shape of a feed horn or of a focused reflector surface is modified to achieve the desired radiation pattern. For example, an elongated shaped aperture will produce an elongated beam, an elliptical shaped aperture will produce an elliptical beam, etc. However, this technique is limited to simple geometric shapes, whereas many designs require various irregular and/or complex shapes.
Beam shaping with a shaped surface reflector antenna consist of a single feed horn illuminating an irregularly contoured reflector surface. Coherent circularly polarized electromagnetic energy is radiated from the feed horn to the irregularly contoured reflector surface. The path length from the feed horn to the reflector surface alters the phase of the corresponding reflected beams. The combined radiation beam from the various phase reflected beams create the desired radiation pattern. This technique is suitable for numerous desired radiation pattern shapes, but is difficult and expensive to construct, since the reflector surface must be machined to the required contour. Additionally, shaped surface reflector antennas are limited to a single radiation pattern. Moreover, the phase relationship between adjacent points on the reflector surface often creates discontinuities in the reflector surface. Therefore, the phase difference between adjacent points on the reflector surface is typically limited to less than 90°. This inhibits a step type surface from being created which generate the discontinuities and poses a difficult machining process.
In an array fed parabolic reflector antenna, multiple feed horns generally illuminate a parabolic reflector. The combined radiation beam from each feed horn, adjusted with the right phase and amplitude, produces the desired radiation pattern. This technique suffers from several drawbacks including RF loss, decrease in antenna gain, control problems, cost and complexity, thereby making its use less attractive.
The microstrip reflectarray antenna consist of radiator elements arranged on a planar aperture. The radiator elements are connected to short circuit terminations and are illuminated by a feed horn. When illuminated, these radiator elements will re-radiate their illuminated electromagnetic energy back into space. To control the radiation pattern, the path lengths from the feed horn to the short circuit terminations are controlled, which in turn, control the phase of the re-radiated beams. Transmission lines of different lengths are connected between the radiator elements and the short circuit terminations to alter the path lengths and phase of the re-radiated beams. The disadvantages of this antenna are its very stringent design tolerances and a rigorous analytical technique to accurately control and model the radiation pattern.
The current antennas and techniques described, each shape a predetermined radiation pattern. However, each antenna and technique have disadvantages that affect their cost, complexity and feasibility. What is needed then, is a beam shaping antenna for radiating a predetermined radiation pattern which is cost efficient, easily manufactured, capable of radiating complex, irregularly shaped radiation patterns, not limited to a single radiation pattern or phase adjustment, maintains good antenna gain and has wider tolerance requirements. It is therefore an object of the present invention to provide such a device.
SUMMARY OF THE INVENTION
In accordance with the present invention, a predetermined electromagnetic radiation pattern is created by shaping a beam of radiation from a circularly polarized beam shaping antenna. This is basically achieved by physical rotation of circularly polarized radiator elements on a ground plane, wherein the rotation alters the phase of each radiator element such that the combined radiation from each individual radiator element shapes a combined beam to create a predetermined radiation pattern.
In one preferred embodiment, a circularly polarized feed horn generates the beam of radiation to be shaped. A number of circularly polarized radiator elements attached to a ground plane and connected to short circuit terminations by transmission lines are positioned to receive the radiated beam. The radiator elements are rotated relative to the ground plane, thereby altering the phase of each element. Each element individually radiates a beam to form the combined radiation beam which creates the predetermined radiation pattern.
In another preferred embodiment, the circularly polarized feed horn again generates the beam of radiation to be shaped. The circularly polarized radiator elements are attached to a first ground plane and are positioned to receive the radiated beam. Each radiator element is further connected in conjugate pairs to radiator elements attached to a second ground plane by transmission lines. The radiator elements on the second ground plane are rotated relative to the ground plane, thereby altering the phase of each element. Each element attached to the second ground plane individually radiates a beam to form the combined radiation beam creating the predetermined radiation pattern. This radiation pattern propagates through space in the same direction as the feed horn radiation pattern.
The present invention provides a circularly polarized beam shaping antenna which is capable of radiating complex, irregularly shaped radiation patterns in a cost efficient, easily manufactured way. The pattern characteristic can be limited to a single radiation pattern or multiple patterns. Furthermore, the antenna is capable of good antenna gain with wide tolerance requirements. As a result, the aforementioned problems associated with currently available beam shaping antennas and techniques should be substantially eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
Still other advantages of the present invention will become apparent to those skilled in the art after reading the following specifications and by reference to the drawings in which:
FIG. 1 is a perspective view of one preferred embodiment of the subject invention containing a number of circularly polarized crossed dipole radiator elements attached to the concave surface of a parabolic ground plane having a circular circumference and a conical feed horn;
FIG. 2 is an enlarged cross-sectional side view of the embodiment of FIG. 1 taken along the lines 2--2 of FIG. 1 displaying the crossed dipole radiator elements attached to the parabolic ground plane and connected to short circuit terminations by transmission lines;
FIG. 3 is an enlarged perspective view taken about line 3 of FIG. 1 of a crossed dipole radiator element;
FIG. 4 is a perspective view of another preferred embodiment of the subject invention containing a number of circularly polarized crossed dipole radiator elements attached to a first planar ground plane and a second planar ground plane having elliptical circumferences and a pyramidal feed horn;
FIG. 5 is a cross-sectional side view of the embodiment of FIG. 4 taken along the lines 5--5 of FIG. 4;
FIG. 6 is an enlarged cross-sectional side view of FIG. 5 taken about line 6, displaying a pair of crossed dipole radiator elements attached to the first planar ground plane and the second planar ground plane and connected by a transmission line;
FIG. 7 is a perspective view of a spiral radiator element; and
FIG. 8 is a front view of a microstrip/patch radiator element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description of the preferred embodiments concerning circularly polarized beam shaping antennas is merely exemplary in nature and is in no way intended to limit the invention or its application or uses.
Referring to FIG. 1, a perspective view of a circularly polarized beam shaping antenna 10, according to one preferred embodiment of the present invention, is shown. The circularly polarized beam shaping antenna 10 includes a circularly polarized conical feed horn 12 having a circular aperture 14. Conical feed horn 12 is preferably located at the focal point of a parabolic ground plane 16 having a circular circumference. The location of the conical feed horn 12 provides a -10 db edge taper at the edge of the ground plane 16. One skilled in the art would further recognize that the ground plane 16 can also include other surface contours, sizes and circumferences, depending on the design constraints and parameters desired. Moreover, the ground plane 16 is preferably constructed of an electrically conductive aluminum alloy material. However, the ground plane 16 can also be constructed of other electrically conductive materials such as various alloys, graphite or conductive mesh.
The conical feed horn 12 generates a circularly polarized beam of radiation (not shown). This beam of radiation illuminates a series of circularly polarized crossed dipole radiator elements 18, attached to the parabolic ground plane 16. One skilled in the art would also find it apparent that the conical feed horn 12 can consist of any type of feed horn capable of generating a circularly polarized beam of radiation. This circularly polarized beam of radiation includes an electric field which rotates about the direction of propagation so that the electric field from the beam makes one full rotation for each wavelength it advances. Furthermore, the frequency and amplitude of the circularly polarized beam as well as the path length from the conical feed horn 12 to the crossed dipole radiator elements 18 will vary depending on the design constraints and parameters desired.
Referring to FIG. 2, a side view of the crossed dipole radiator elements 18, attached to the parabolic ground plane 16, is shown. Crossed dipole radiator elements 18 are connected to short circuit terminations 20 by transmission lines 22. Transmission lines 22 are preferably high frequency semi-rigid coaxial cables having inner and outer conductors. Alternatively, transmission lines 22 can consist of any type of transmission line capable of transmitting high frequency electrical signals. The short circuit terminations 20 join the inner and outer conductors of transmission lines 22, thereby making the conductors common. The radiator elements 18, transmission lines 22 and short circuit terminations 20 are operable to receive and re-radiate the circularly polarized beam of radiation. Crossed dipole radiator elements 18 also include slip joints 24 which accommodate the rotation of crossed dipole radiator elements 18 relative to the ground plane 16. Slip joints 24 can also be substituted by other rotational mechanisms to enable rotation of the crossed dipole radiator elements 18.
Referring to FIG. 3, each of the crossed dipole radiator elements 18 consist of a dipole arm 26 extending perpendicular to a dipole arm 28 having a split balun 30. The diameter of the dipole arms 26 and 28 control the bandwidth of the radiated beam, while the length of the dipole arms 26 and 28 control the frequency of the radiated beam. The unequal lengths of the crossed dipole arms 26 and 28 in conjunction with opposite polarities on either side of the split balun 30, produces the circular polarization. The crossed dipole radiator elements 18 are preferably constructed of a conductive graphite material. However, crossed dipole radiator elements 18 can also be constructed of various other conductive materials, including aluminum and metal alloys.
In operation, the conical feed horn 12 generates the circularly polarized beam of radiation which is received by the crossed dipole radiator elements 18. The circularly polarized beam impinges the crossed dipole radiator elements 18 and propagates through the transmission lines 2 to the short circuit terminations 20. The transmission lines 22 act as waveguides which support propagation of the radiated beam received by crossed dipole radiator elements 18. After propagating through the transmission lines 22, and arriving at the short circuit terminations 20, the circularly polarized beams are reflected back such that the beams propagate through transmission lines 22 and out the crossed dipole radiator elements 18. This causes each crossed dipole radiator element 18 to radiate an individual circularly polarized beam of radiation having the same polarization as the incident beam from the feed horn.
The phase of the individual beams radiated from each crossed dipole radiator element 18 is altered by the physical rotation of the crossed dipole radiator elements 18, relative to the ground plane 16, employing slip joints 24. For example, if the crossed dipole radiator element 18 is rotated clockwise +45°; (as viewed from the front of the crossed dipole radiator element 18) the phase of the radiated beam from the crossed dipole radiator element 18 will lead by +45°. Conversely, if the crossed dipole radiator element 18 is physically rotated counterclockwise -45°, the radiated beam will lag by -45°. The individual radiation from each crossed dipole radiator element 18 thus forms a combined radiation beam in the far field creating a predetermined radiation pattern. This radiation pattern may cover a particular portion of a state, country or continent and selectively exclude various other areas.
Referring to FIGS. 4-6, another preferred embodiment of a circularly polarized beam shaping antenna 32, is shown. Circularly polarized beam shaping antenna 32 includes a circularly polarized pyramidal feed horn 34 having a rectangular aperture 36. The pyramidal feed horn 34 is preferably located at the focal point of a first planar ground plane 38. The pyramidal feed horn 34 generates the circularly polarized beam of radiation. This beam of radiation illuminates a series of circularly polarized crossed dipole radiator elements 40, attached to the elliptically shaped first planar ground plane 38. The crossed dipole radiator elements 40 are operable to receive the circularly polarized beam of radiation.
A number of crossed dipole radiator elements 42 are attached to a second planer ground plane 44, also having an elliptical circumference. Ground plane 44 is positioned opposite to the feed horn 34 such that it is substantially aligned with the first planar ground plane 38. The crossed dipole radiator elements 40, are connected in conjugate pairs to the crossed dipole radiator elements 42, by means of a series of transmission lines 46, shown more clearly in FIGS. 5 and 6. Crossed dipole radiator elements 42 are operable to radiate the circularly polarized beam of radiation. Each of the radiator elements 40 and 42 are substantially identical to the radiator elements 18, above. The crossed dipole radiator elements 42 further include a series of slip joints 48 which provide for the rotation of the crossed dipole radiator elements 42 relative to the second ground plane 44.
In operation, the pyramidal feed horn 34 generates the circularly polarized beam of radiation which is received by the crossed dipole radiator elements 40. The circularly polarized beam impinges the crossed dipole radiator elements 40 and propagates through the transmission lines 46 connecting the crossed dipole radiator elements 40 and 42. After propagating through the transmission lines 46, the circularly polarized beam propagates out the crossed dipole radiator elements 42. This causes each crossed dipole radiator element 42 to radiate an individual circularly polarized beam of radiation in the same direction as the radiated beam from the pyramidal feed horn 34. The phase of each beam is similarly altered by physical rotation of the radiator elements 42 relative to the second ground plane 44 by means of the slip joints 48. The individual radiation beam from each crossed dipole radiator element 42 forms a combined radiation beam in the far field creating the predetermined radiation pattern.
Referring to FIGS. 7 and 8, a spiral radiator element 50 and a microstrip/patch radiator element 52, are shown. The spiral radiator element 50 and microstrip/patch radiator element 52 can be substituted for any of the crossed dipole radiator elements 18, 40 and 42 discussed above. Each radiator element 50 and 52 is capable of radiating a circularly polarized beam of radiation and is similarly capable of altering the phase of its beam by physical rotation of the radiator element relative to a ground plane. The spiral radiator element 50 and the microstrip/patch radiator element 52 are preferably made of copper, however, radiator elements 50 and 52 can also be constructed of aluminum, graphite or other suitable electrically conductive materials. As such, one skilled in the art would readily recognize that radiator elements 50 and 52, as well as other radiator elements capable of radiating a circularly polarized beam of radiation, can be used with the beam shaping antennas discussed above.
The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention as defined by the following claims. | Disclosed is an apparatus and method for shaping a beam of radiation from a circularly polarized beam shaping antenna to create a predetermined radiation pattern. A circularly polarized feed horn generates the beam of radiation to be shaped. Circularly polarized radiator elements attached to a ground plane are positioned to receive the beam of radiation. Each radiator element is physically rotated about an axis relative to the ground plane to alter its phase. The radiator elements are then operable to individually radiate a beam of radiation to form a combined radiation beam creating the predetermined radiation pattern. | 7 |
RELATED APPLICATIONS
[0001] This application claims benefit to U.S. provisional application Ser. No. 60/553,513 filed Mar. 16, 2004, which is incorporated by references for all useful purposes.
GOVERNMENT LICENSE RIGHTS
[0002] This work was conducted under a grant from National Science Foundation, grant nos. DMR-0210223 and CHE-0346454.
BACKGROUND OF THE INVENTION
[0003] In the prior art it is well known to color materials using dyes and pigments. Unfortunately, pigment and dye coloration agents suffer fading effects due to exposure to ultraviolet light, ozone or bleach. The usual cause of this fading is chemical changes in the colorant. These chemical changes alter the electronic transitions of the colorant, thereby causing undesired instability in color.
[0004] One reason for the fading of the dyes is that the dyes are coated to the surface of the fiber instead of being mixed throughout the fiber.
[0005] The investigation of structure/property relationships in materials often requires processing prior to the measurement of these properties. Fiber spinning is often the processing method of choice in long chain polymers because of the subsequent chain alignment that occurs during the shear and windup process. This alignment can give rise to highly anisotropic electrical, mechanical and photonic properties. Unfortunately commercial spinning lines need large (5-10 lbs) quantities of starting material in order to produce melt-spun fibers. This limits the candidates for investigation to those that are made in sufficiently large quantities and/or those that do not degrade at elevated temperatures, in the case of melt spinning. Solution spinning is possible as an alternative method but has been reserved for those polymers that dissolve in volatile and often times aggressive solvents (e.g., Kevlar in sulfuric acid).
[0006] It would be advantageous to provide improved methods of coloration that provide switchability from one color state to another. Such color changing compositions can be used, for example, for cosmetic purposes in polymer fibers used for textiles and carpets and for color-changing windows and displays, sensors (chemical sensor, pressure sensor, light sensor) and optical storage devices. Additionally, this type of technology could be used in military applications for camouflage clothing, tents, and machinery. If such color change is reversibly switched as a consequence of light exposure then chameleon effects can be achieved for such articles.
[0007] Although photochromic molecules have been embedded in polymer films, the advantage of having successfully incorporated them in fibers is that the surface area of these micro- and nanodiameter fibers is such that exposure to light uniformly converts the photochromic molecules to another color whereas in films, often the thickness (10-50 microns) prevents a complete color change in the interior of the film or it takes a long time that in many applications is not acceptable. In addition, the availability of single small fibers with photochromic properties should allow the development of an optical switch on the micron and submicron scale.
[0008] The electrospinning of fibers has been investigated for more than 30 years. However, since 1998 the number of publications on electrospun polymer nanofibers have grown exponentially, Z. M. Huang, Y. Z. Zhang, M. K. Kotaki and S. Ramakrishna, Composites Sci. and Tech. 2003, 63, 2223-2253 (“Huang”), US20030137069. Electrospinning, an offshoot of electrospraying, can be used to spin spider-web type fibers (see FIG. 1 ) for characterization and testing of their mechanical and surface properties. The fibers produced during the electrospinning process are micro- and nanoscale, with diameters ranging (D. H. Reneker and I. Chun, Nanotechnology 1996, 7, 216 (“Reneker”)) from 40 nm to 5 μm compared to traditional textile fibers which have diameters (Reneker) of 5 to 200-μm. The primary advantage of electrospinning is that it uses minute quantities (as little as 10-15 mg) of polymer in solution to form continuous fibers. A second advantage is that additional components, e.g., small “guest” molecules, nanoparticles or a second polymer can be added to the polymer solution and under certain conditions be incorporated into the fiber during the electrospinning process. Although a number of commodity polymers have already been electrospun (Huang and S. Megelski, J. S. Stephens, D. B. Chase and J. F. Rabolt, Macromolecules 2002, 35, 8456 (“Megelski”), an understanding of the mechanism and parameters that affect the electrospinning process is only starting to emerge. There are a limited number of parameters that appear to effect the fiber diameter, the concentration of “beads”, the fiber surface morphology and the interconnectivity of polymer fibrils. These include solution concentration, distance between “nozzle” and target, molecular weight of the polymer, spinning voltage, humidity, solvent volatility and solution supply rate. Although some of these (e.g., molecular weight, humidity) have been investigated in detail (C. Casper, J. Stephens, N. Tassi, D. B. Chase and J. Rabolt, Macromolecules 2004, 37, 573-578 (“Casper”) and Megelski most of the work has focused on investigation of the development of microstructure in fibers and their potential applications ranging from tissue engineering constructs to fuel cell membranes.
[0009] Photochromic materials are those whose color can change reversibly depending on the wavelength of light they are exposed to. The process of reversibility comes about when the material is exposed to light of a different wavelength than that used initially to induce the color change and, as a result, the material returns to its original color (J. Wittal, Photochromism, Molecules and Systems , Eds. H. Durr, H. Bouas-Laurent Elsevier, Amsterdam, 1990 (“Wittal”) and M. Irie, Chem. Rev. 2000, 100, 1685-1716 (“Irie”). Usually, organic photochromic molecules are highly aromatic chromophores that reversibly rearrange their electronic structure in response to certain wavelengths of light. An example of one such class of organic reversible photochromic materials are the diarylethenes (Irie). These molecules undergo changes in their electronic structure via a rearrangement of the bonds that comprise their ringed architecture as shown below:
[0010] Two forms of diarylethylene are shown above: “open”—left; “closed”—right. A and B are pendant groups that can be used to tune solubility and/or absorption characteristics. This leads to the “open” and “closed” form ring structures with the former absorbing in the visible (500-700 nm) and the latter absorbing in the UV (250-300 nm). This class of molecules has a good fatigue resistance and also good thermal stability which makes them good candidates for application in many fields.
[0011] Applications of these diarylethenes and numerous other photochromic materials in nonlinear optics, read-write storage materials, optical switches (Irie) and tuneable masks (E. Molinari, C. Bertarelli, A. Bianco, P. Bortoletto, P. Conconi, G. Crimi, M. Galazzi, E. Giro, A. Lucotti, C. Pernechele, F. Zerbi and G. Zerbi, Proceedings of SPIE Hawaii 2002, Vol. #4842-18, p. 335-342 (“Molinari”)) depends on the amount of these conjugated structures that can be incorporated into a host material, such as a polymer, to impart mechanical strength, oxidation resistance, and robustness. Traditionally the way this has been accomplished is through the incorporation of the conjugated molecule directly into the polymer film as an additive. This can lead to phase separation when the amount of photochromic material exceeds 5-6%. At higher concentration levels, problems with homogeneity often occur. A second approach has been to append the photochromic groups as side chains to a polymer backbone. Although this allows the concentration of photochromic groups in the sample to be increased, it also drastically reduces the quantum yield thus compromising the photochromic properties of the material. Stellaci et al. (F. Stellaci, C. Bertarelli, F. Toscano, M. Gallazzi, G. Zotti and G. Zerbi, Adv. Materials 1999, 11, 292-295 (“Stellaci”) were able to solve this problem by synthesizing the first diarylethylene backbone polymer whose thermal stability was higher than the monomer. They showed that the polymer exhibited photochromism both in solution and in the solid state with a very high quantum yield for the “closed” form reaction.
BRIEF SUMMARY OF THE INVENTION
[0012] We found that the incorporation of photochromic materials or any dyes into electrospun fibers gives excellent results. If the dyes are capable of forming color then there can be two different reversible patterns depending on the exposed light wavelength. If the dyes are not photochromic, then the pattern becomes a permanent pattern with the dyes being distributed throughout the fiber and not just on the surface of the fiber as is currently being done by dyed materials.
[0013] The invention encompasses the incorporation of molecules such as dyes or reversible photochromic molecules (e.g., dyes) into micro- and nanofibers through the electrospinning process. In this process, a solution of a polymer (such as polymethylmethacrylate (PMMA)) and the photochromic molecule is shaped into a small diameter fiber by the application of electrostatic forces using electric fields that vary, for example, from 300-2000 volts per centimeter. The resulting fibers are collected on a target that can be electrically grounded or held at a voltage lower (or oppositely charged) than that of the “nozzle” where the droplet of polymer/photochromic molecule first emerges from the reservoir of solution. The fibers have diameters that range from 1-2 microns to 10 s of nanometers and have been shown to contain a uniform distribution of photochromic molecules throughout. Mats, membranes and nonwoven textiles formed from these fibers have been shown to reversibly change color depending on the wavelength of light they are exposed to. Uses range from nonwoven textiles and membranes that change color depending on the amount and wavelength of light impinging on them (which includes camouflage material), sensors, sensing membranes, counterfit protector, information storage and optical switches.
[0014] The invention relates to a process to make a dyed fiber which comprises mixing a dye and a polymer into a solution at a temperature below the temperature at which the dye or polymer degrades, preferably at room temperature (approximately 23° C.) or slightly higher but not above the temperature that the dye degrades or oxides, to form a polymer dye solution and electrospinning said polymer dye solution to form a fiber wherein the dye penetrates more than the surface of the fiber. The dye can be a photochromic (for reversal color) or non photochromic (for permanent color).
[0015] The invention further relates to a fiber or fibril made by said process.
[0016] Another object of the invention is that the fibers can be used to make material that can be worn in activities, such as paint ball, laser tag, or with soft guns. The sensors could be used for activities such as paint ball or with air soft guns. The user would wear clothing made of a material that can change colors. The material could change colors by pressure such as when it is in contact with a pellet such as one from an air soft gun. The material could be pressure sensitive and would change colors at the point of impact. The material could change color by light such as when it is hit with a laser light. The point of impact would change color because the material would be light sensitive.
BRIEF DESCRIPTION OF THE FIGURES
[0017] FIG. 1 illustrates twisted dog-bone shaped fiber (left) typically found in electrospun samples made from 35 wt % polystyrene (PS) in the tetrahydrofuran (THF). An expanded view is shown on the right in FIG. 1 .
[0018] FIG. 2 illustrates the fiber under an optical microscope (left-20x) and FE-SEM (right) of PMMA+DYE1 fibers.
[0019] FIG. 3 illustrates fluorescence confocal images of PMMA+DYE1 taken at two different depths of the same fiber.
[0020] FIG. 4 illustrates fluorescence confocal images of PMMA+DYE1, showing the distribution of active photochromic molecules throughout the two fibers shown. The insets represent the DYE1 distribution across an arbitrarily chosen “slice” that traverses the fiber diameter.
[0021] FIG. 5 illustrates a bundle of aqua colored fibers with yellow circular areas after exposure to laser light at 532 nm. Left: DYE1+PMMA. FIG. 5 also illustrates bundle of deep blue colored fibers with white circular area after exposure to laser beam light at a wavelength of 532 nm Right: DYE2+PMMA.
[0022] FIG. 6 illustrates mat of electrospun PMMA+Dye 1 fibers. The dye is in the closed form.
[0023] FIG. 7 a ) illustrates a Mat of PMMA+Dye 1 blue fibers locally exposed to a white light. FIG. 7 b ) illustrates the same blue fiber mat after subsequent exposition to UV radiation. The UD emblem disappeared.
[0024] FIG. 8 a ) illustrates a mat of PMMA+Dye 3 fibers locally exposed to UV radiation. FIG. 8 b ) illustrates the same fiber mat after stored at 26° C. shielded from UV radiation for 20 minutes.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The invention again relates to a method of making a fiber that incorporates a dye into the fiber. The dye is uniformly dispersed throughout the fiber and not just on the surface. The dye can be any known dye. As examples of substances belonging to this group, there are known photochromic compound, solvatochromic compound, magnetochromic, electrochromic, thermochromic compound, piezochromic compound, and leuco bodies such as triarylmethane dyes, quinone dyes, indigoide dyes, azine dyes and so on. Each of these compounds can change its color by the application of solvent (gaseous or liquid), heat or pressure, irradiation with light, or air oxidation.
[0026] If the dye used is not photochromic, the color can permanent. If the desired results of the finished product are to have a reversible pattern depending on the light, then the dye used would be a photochromic dye. For example, if clothing is made using fibers containing photochromic dyes, then the clothing can have at least two different patterns or even three or more different patterns depending on the exposure of the clothing to region of light. If the light is in the visible region one pattern can exist, if the exposure is night time with out light, then another pattern can exist, if the clothing is under ultraviolet light a third pattern can exist. If multiple photochromic dyes are used in the fibers, the fibers will change color depending on the type of photochromic dye used and the wave length of the light the fiber is exposed to. It would be possible to use multiple different fibers in an article with each of the fibers having different colors, depending on which wavelength of light the fibers are exposed to. For example, if the desired results are to make a camouflage clothing, tents, and machinery or cover for machinery, then the material can change colors depending on whether it is daytime or nighttime to blend into the surroundings. With respect to camouflage material, the material can be a lighter color in the light similar to the surroundings and become a darker color at night to blend in with the surroundings.
[0027] The fibers are made from a polymer dye solution by an electro spinning process as described in Reneker, U.S. Pat. No. 4,323,525, U.S. Pat. No. 4,689,525, US 20030195611, US 20040018226, and US 20010045547, which are incorporated herein by reference.
[0028] The following patents which are incorporated by reference contain, by example, are the preferred photochromic dyes: U.S. Pat. No. 5,213,733, U.S. Pat. No. 5,422,181, U.S. Pat. No. 6,440,340, U.S. Pat. No. 5,821,287, US20020188043, US20030213942, US20010045547, US20030130456, US20030099910, US20030174560 and the references contained therein.
[0029] The polymers that are preferably used are listed in Huang, US 20030195611, US 20040037813, US 20040038014, US 20040018226, US20040013873, US 2003021792, US 20030215624, US 20030195611, US 20030168756, US 20030106294, US 20020175449, US20020100725 and US20020084178 which are all incorporated by reference.
[0030] The pigment can further be used as a monomer for copolymerization and/or to be blended with low melting point polyester, polydimethyl isophthalate (DMI), polypropylene (PP), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polycarbonate, polystyrene, polyvinylidene chloride, polyvinylidene fluoride, polyethyleneoxide, nylon 6, nylon 6/6, nylon 11, nylon 12 or mixtures thereof and its blends etc. for preparation of photochromic fibers.
[0031] The preferred solvents that may be used are (a) a high-volatility solvent group, including acetone, chloroform, ethanol, isopropanol, methanol, toluene, tetrahydrofuran, water, benzene, benzyl alcohol, 1,4-dioxane, propanol, carbon tetrachloride, cyclohexane, cyclohexanone, methylene chloride, phenol, pyridine, trichloroethane or acetic acid; or
[0032] (b) a relatively low-volatile solvent group, including N,N-dimethyl formamide (DMF), dimethyl sulfoxide (DMSO), N,N-dimethylacetamide (DMAc), 1-methyl-2-pyrrolidone (NMP), ethylene carbonate (EC), propylene carbonate (PC), dimethyl carbonate (DMC), acetonitrile (AN), N-methylmorpholine-N-oxide, butylene carbonate (BC), 1,4-butyrolactone (BL), diethyl carbonate (DEC), diethylether (DEE), 1,2-dimethoxyethane (DME), 1,3-dimethyl-2-imidazolidinone (DMI), 1,3-dioxolane (DOL), ethyl methyl carbonate (EMC), methyl formate (MF), 3-methyloxazolidin-2-on (MO), methyl propionate (MP), 2-methyletetrahydrofurane (METEF) or sulpholane (SL).
[0033] Other solvents that can be used are listed in US20020100725 and US20030195611, which are incorporated by reference. CHCl 3 is the solvent used in the examples.
[0034] The amount of polymer and solvent will vary from 0.1-100%, the latter being pure polymer which can only be electrospun from the melt. The concentration of polymer and solvent can be the same as discussed in the electrospinning publications and patents, Reneker, Megelski, Casper, U.S. Pat. No. 4,323,525, U.S. Pat. No. 4,689,525, US 20030195611, US 20040018226 and US 20010045547, which are all incorporated herein by reference.
[0035] Electrospinning or electrostatic spinning is a process for creating fine polymer fibers using an electrically charged solution that is driven from a source to a target with an electrical field. Using an electric field to draw the positively charged solution results in a jet of solution from the orifice of the source container to the grounded target. The jet forms a cone shape, called a Taylor cone, as it travels from the orifice. Typically, as the distance from the orifice increases, the cone becomes stretched until a single fiber originates and travels toward the target. Also prior to reaching the target, and depending on many variables, including target distance, charge, solution viscosity, temperature, solvent volatility, polymer flow rate, and others, the fibers begin to dry. These fibers are extremely thin, typically measured in nanometers or microns. The collection of these fibers on the target, form a randomly-oriented fibrous material with extremely high porosity and surface area, and a very small average pore size.
[0036] The basic components required for solvent electrospinning are as follows: A polymer is mixed with a solvent to form a solution having desired qualities. The solution is loaded into a syringe-like container that maybe fluidly connected to a blunt needle to form a spinneret. The needle has a distal opening through which the solution is ejected by a controlled force, represented here in a simplified manner as being supplied by a plunger but can be any appropriate controllable variable rate fluid displacement system and should be automated to ensure accurate flow rates.
[0037] Dyes can be incorporated into the fibers when the electrospinning process is carried out at temperatures ranging from a lower limit at which the solvent freezes to an upper limit where the dye degrades. The dyes do not degrade in the electrospinning process because they are done at moderate temperatures in solution compared to the melting point of the polymers used.
[0038] It turns out the dye can be mixed into the polymer solution, added to the same solvent as used for the polymer and then the two solutions added together or mixed with the polymer in a dry form and then both dissolved in the solvent This may differ for the various polymers and dyes used.
EXAMPLES
[0039] The examples contain fibers that consist of a polymer matrix. PMMA (M w =540,000), in which is embedded the following photochromic molecules:
wherein n is average of 7-8.
DYE 3 is the same chemical formula as DYE 1 with n being 1.
[0040] DYE 1, shown above is a photochromic backbone polymer that contains 7-8 repeat units (Degree of Polymerization (DP)=7-8), while DYE 2, shown above is a photochromic molecule with a specifically chosen end group (Stellacci F, Bertarelli C, Toscano F, Gallazzi M C, Zerbi G, CHEM PHYS LETT 302 (5-6): 563-570, 1999 (“Stellacci”). DYE 3 is the same chemical formula as DYE 1 with n being 1.
[0041] To prepare the electrospun fibers, PMMA and either DYE1 or DYE2 are dissolved in CHCl 3 using the specific concentrations shown in Table 1. The resultant DYE1 (or DYE2)+PMMA solution is then electrospun using established processing protocols. The specific parameters used for the first set of experiments described below are summarized in Table 1:
TABLE 1 Concentration Voltage kV Speed Rate H/T 10%(+5% DYE1) 10 0.1-0.15 ml/min 36%/70 F. 5.6%(+5% DYE1) 12 0.12 ml/hr 56%/72 F. 10.8%(+5.4% DYE2) 10 0.12 ml/hr 17%/70 F.
[0042] In Table 1 the conditions used for the electrospinning of the photochromic fibers are as follows: Concentration is in wt %, Voltage is the potential of the syringe nozzle relative to the grounded target; Speed Rate is the amount of solution provided to the syringe nozzle; H/T is the relative humidity and temperature at the time the electrospun fibers were produced.
[0043] As a result of electrospinning the DYE/PMMA solutions, fibers whose diameters range between 1 and 10 microns are produced depending on the concentration of PMMA in CHCl 3 . Under other conditions, fibers smaller and bigger than this range have been produced by the electrospinning process as described in Megelski, “Stephens” (J. S. Stephens, J. F. Rabolt, S. Fahnestock and D. B. Chase, MRS Proceedings 774, 31 (2003)), US20030195611 and US20030168756 which are incorporated by reference.
[0044] Because of the low molecular weight of the photochromic molecules and their low concentration in the solution, it was determined that their effect on the fiber diameter was negligible. Although the preferable amount of dye in the fiber is from about 0.1 to about 15 wt %, although it is possible that the amount of the dye could be more provided that the maximum concentration of dye cannot exceed the amount where fibers are no longer formed. If the dye is covalently incorporated in the polymer backbone or covalently attached as a side chain, then the preferable amount of dye can be increased to a higher wt % depending on the molecular weight of the dye chromophore relative to the molecular weight of the monomer.
[0045] The as-produced fibers have been studied using both optical and field emission scanning electron microscopy (FE-SEM) in order to ascertain any surface topography that may exist and to determine the presence of any morphological defects. As seen in FIG. 2 , the cross-sectional shape of the fibers adopts a “dog-bone” shape similar to that usually found in PMMA and PS (see FIG. 1 ) fibers (see Megelski). It is also clear from FIG. 2 that no beads or other morphological defects are present The surface of the fibers contains nanopores that increase the active area of the fiber significantly. The average diameter of these pores is approximately 200 nm but Megelski and Casper have produced electrospun fibers with pores that range from 50-1000 nm under different conditions.
[0046] To understand the distribution of the active molecules in the fibers, fluorescence measurements using a confocal microscope (Zeiss LSM510) were performed. FIG. 3 contains fluorescence images taken at two different depths within the fiber. The fact that both images show uniform green color due to fluorescence is indicative that the DYE1 is uniformly distributed throughout the fibers. The DYE1 distribution across an arbitrarily chosen “slice” that traverses the fiber diameter for two fibers is shown in FIG. 4 and also indicates that the distribution of the photochromic molecules (DYE1) across the fiber is uniform.
[0047] The observed color of the fibers is blue when they are irradiated with UV light and it switches to yellow for DYE1 and to white for DYE2 when a green laser is used (532 nm) to irradiate a collection of fibers as shown in FIG. 5 . In the left of FIG. 5 , blue DYE1+PMMA electrospun fibers were exposed to a circular laser beam of 532 nm in two locations where the fiber bundle is seen to have changed to yellow. Re-exposing these areas to UV light changes these areas back to blue. This switching procedure is reversible and from cyclic studies on DYE1+PMMA films, it has been shown that this change in color can be repeated for at least 400 times without loss of performance. This is a key factor for practical applications of these fibers in nonwoven textiles, optical switches and sensors.
[0048] As shown by the right portion of FIG. 5 , DYE2+PMMA fibers exhibit a different blue color due to the difference in the absorption characteristics of DYE2. In this case irradiation using a 532 nm wavelength, circular diameter laser beam changes the exposed area from light blue to white. Therefore it is possible to mix different photochromic materials in the same electrospun fibers or co-process different electrospun fibers containing other photochromic molecules in order to increase the number of colors available and then switching them to alternative colors upon exposure to various wavelengths of light.
[0049] As a particular example, if lasers were used, one could practice this invention by reversibly storing information on the fibers depending on the wavelength of laser used. Since the spatial resolution depends on the wavelength of irradiation, in the example described above a 532 nm laser wavelength laser can be used to “write” features of approximately 250 nm in size on the fibers. With the large surface area available as mentioned previously and the 3-D nature of the electrospun fiber membranes, it could be possible to store information in 3-D at densities comparable to or higher than current day magnetic and optical storage devices.
[0050] The specific parameters used for the second set of experiments described below are summarized in Table 2:
[0051] Table 2 Conditions used for the electrospinning of the photochromic and thermochromic fibers (Note: Concentrations are in weight % of PMMA with respect to the solvent and in brackets the concentration in weight % of photoactive molecule with respect to the polymer matrix; Potential is the potential applied to syringe needle relative to the grounded target; Solution flow rate is the flux of solution at the needle tip; H/T are the relative humidity and temperature at the time the electrospun fibers were produced; Color is the color of the open and closed form, respectively).
TABLE 2 Solution Concentration Potential flow rate H/T Color 12% (+5% Dye 1) 10 kV 1.5 ml/hr 36%/21 C. Yellow/blue 12.6% (+5.4% Dye 2) 10 kV 0.4 ml/hr 17%/21 C. White/blue 13% (+6% Dye 3) 11 kV 1.2 ml/hr 50%/26 C. White/pink
[0052] FIG. 6 shows a dense mat of PMMA+Dye 1 fibers collected in approximately fifteen minutes. In this case, the fabric has been irradiated by a UV lamp (366 nm) for an extended period of time (˜3 minutes) to assure that a maximum number of dye molecules throughout the entire thickness have switched from the open to the closed form resulting in the deep blue color. A pattern was then “printed” on the same membrane. A mask with a 1.7×1.2 cm “UD” symbol was created on a regular transparency sheet using a normal laser printer. This mask was used to cover the entire fiber mat except for the area of the symbol. FIG. 7 a shows the mat after it was exposed for less than a minute to a 300 W halogen lamp. The light was filtered to remove the UV tail of the emission spectrum. In this case, the exposed dye molecules switched to the open form, resulting in a color change from blue to yellow. The right part of the figure ( FIG. 7 b ) shows the same area of the mat after the removal of the symbol by the exposure to UV light, comprising the reversibility of the process. An optical fatigue study on PMMA+Dye 1 films has shown that this change in color can be repeated at least 400 times without a loss of performance. (A. Lucotti, C. Bertarelli and G. Zerbi, Chem. Phys. Lett., 392, 549, (2004)). However, this study was conducted on films and not conducted on fibers. This is a key factor for practical applications of these fibers in non-woven textiles, optical switches and sensors.
[0053] A second non-woven membrane/mat was created by electrospinning PMMA+Dye 3 fibers. This thermochromic dye is colorless in the open form and pink in the closed form. The left side of FIG. 8 shows the mat after the exposure of a triangular area (base of triangle: ˜12 mm) to UV light for about three minutes. For this sample, the mask was created in a piece of aluminum foil. The left side of the figure ( FIG. 8 a ) shows the mat/membrane immediately after the exposure. The color of the triangle is a deep pink indicating a high conversion from the opened to closed forms. FIG. 8 b shows the same area of the mat after it was stored for 20 minutes at 26° C. while being shielded from UV radiation. The triangle is now clearly dimmer, indicating that a certain fraction of dye molecules have switched to the closed form. At room temperature, the switching process is slow for this particular dye molecule. It took 5 days for the pink triangle to completely disappear.
[0054] All the references described above are incorporated by reference in its entirety for all useful purposes.
[0055] While there is shown and described certain specific structures embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described. | A process to make a dyed fiber which has the steps of mixing a dye capable of changing color and a polymer into a solution at a temperature below the temperature at which the dye or polymer degrades to form a polymer dye solution and electrospinning said polymer dye solution to form a fiber wherein the dye penetrates more than the surface of the fiber. The invention also relates to the fiber and use of the fiber. | 3 |
FIELD OF THE INVENTION
This invention pertains to carts with lockable drawers, and more particularly to a locking system for medical carts.
BACKGROUND OF THE INVENTION
Carts with lockable drawers are used for many applications. For example, a medical cart having lockable drawers is used to administer medication to patients in hospitals or other care facilities. A typical medical cart has casters located at the bottom of the cart to permit easy movement of the cart by attending nurses to various patients' rooms. The cart also has one or more drawers for storing patients' medicines. Typically, each drawer is dedicated to storing the medication for an individual patient. Because the cart is used to store medications for several patients and is movable from room to room, controlling access to the contents of the cart to prevent theft or misuse of medication, and thereby protect the patients is important. One such medical cart, as described above, is disclosed in U.S. Pat. No. 5,743,607 to Tuefel et al., which patent is commonly held by the Assignee of the present invention and hereby incorporated by reference in its entirety.
Conventional medical carts have manually actuated locks which are operable to permit users to selectively lock and unlock the drawers of the cart to thereby control access to the contents stored in the drawers. Conventional medical carts have also been provided with electronically actuated locks, whereby the drawers of the cart are unlocked in an automated fashion after a user enters an access code into a keypad located on an external portion of the cart. When medical carts have been provided with both manual and electronically actuated lock mechanisms, these mechanisms have typically been provided as separate and independent systems, each individually capable of releasing the drawers of the cart from a locked condition. Because the manual and electronically actuated systems are separate, this necessarily adds to the overall complexity and cost of the carts.
There is thus a need for a simple cart locking system which overcomes drawbacks of the prior art such as those described above.
SUMMARY OF THE INVENTION
The present invention provides a locking system for a cart wherein a manually actuated lock mechanism is integrated with an electronically actuated lock mechanism to provide a compact and efficient system for controlling access to the contents of the drawers of a cart. It is recognized that unlocking the drawers of a cart using an electronically actuated lock mechanism may be initiated, for example, when a user manually enters an access code into a keypad. Accordingly, reference to the lock mechanisms as “manually actuated” and “electronically actuated,” as used herein, is intended to describe the structure or manner in which the respective lock mechanisms operate to unlock the drawers of a cart.
In an exemplary embodiment, the locking system includes a cam that is operatively coupled to a drawer of the cart to permit the drawer to be secured within the cart. The cam has a locked position wherein the drawer is prevented from being moved from the closed position to the open position, and an unlocked position wherein the drawer is released for movement from the closed position to the open position.
The locking system further includes a manually actuated lock mechanism and an electronically actuated lock mechanism. The manually actuated lock mechanism is operable to permit manual manipulation of the cam between its locked and unlocked positions. In one embodiment, the manually actuated lock mechanism comprises a lock core that is manually movable between a first position corresponding to the locked position of the cam, and a second position corresponding to the unlocked position of the cam.
The electronically actuated lock mechanism cooperates with the manually actuated lock mechanism to permit automatic operation of the locking system as desired. The electronically actuated lock mechanism may be actuated when a user enters an appropriate access code into a keypad on the cart, or may be actuated by a control system of the cart according to predetermined conditions. In an exemplary embodiment, the electronically actuated lock mechanism comprises a release member engageable with the lock core of the manually actuated lock mechanism to permit automatic movement of the lock core between its first and second positions, i.e., from the locked position toward the unlocked position, or from the unlocked position toward the locked position. In another exemplary embodiment, the electronically actuated lock mechanism comprises a drive motor coupled to the release member and configured to selectively move the release member in directions toward the respective first and second positions of the lock core.
In another aspect of the invention, a method of securing contents in a drawer of a cart having a locking system as described above, comprises selectively moving the manually actuated lock mechanism from a locked condition to an unlocked condition to release a drawer of the cart for movement between closed and open positions. In one embodiment, the method includes manually moving the manually actuated lock mechanism from the locked condition to the unlocked condition. In another embodiment, the method includes automatically moving the manually actuated lock mechanism from the locked condition to the unlocked condition.
These and other objects, advantages, and features of the invention will become more readily apparent to those of ordinary skilled in the art upon review of the following detailed description of various exemplary embodiments, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.
FIG. 1 is a perspective view of a medical cart including a locking system incorporating features of the present invention;
FIG. 2 is a partially broken-away perspective view showing detail of the locking system and cart of the encircled area 2 of FIG. 1 ;
FIG. 2A is an enlarged detail view of the locking system of FIG. 2 ;
FIG. 3 is an exploded perspective view of the locking system of FIG. 2A ;
FIG. 4A is a cross-sectional view of the locking system of FIG. 2A , taken along line 4 A— 4 A, and illustrating the locking system in a locked state;
FIG. 4B is a cross-sectional view of the locking system of FIG. 4A , taken along line 4 B— 4 B;
FIG. 5 is a cross-sectional view, similar to FIG. 4A , depicting the locking system manipulated to an unlocked state using a key;
FIG. 6A is a cross-sectional view similar to FIG. 4A , illustrating the locking system in an electronically unlocked state;
FIG. 6B is a cross-sectional view of the lock system of FIG. 6A , taken along line 6 B— 6 B;
FIG. 7A is a cross-sectional view similar to FIG. 4A , illustrating the locking system in a manually locked condition after being unlocked electronically; and
FIG. 7B is a cross-sectional view of the lock system of FIG. 7A , taken along line 7 B— 7 B.
DETAILED DESCRIPTION
Referring to FIGS. 1–2 , a medical cart 10 including a locking system 12 incorporating features of the present invention is shown. The cart 10 has an enclosure 14 which houses a number of drawers 16 , mounted on slides 18 and supported by a chassis or frame structure 20 within the enclosure 14 . A series of locking tabs 22 are secured within the enclosure 14 and are supported by the frame 20 for movement to lock all of the drawers 16 in a closed position. The drawers 16 may be used, for example, to store medicines for individual patients and the cart 10 is provided with casters 24 to enable the cart 10 to be easily moved within a facility so that the cart 10 may be taken to individual patient rooms for administration of the medicines.
Referring now to FIGS. 2 , 2 A and 3 , the locking system 12 of the present invention includes a lock mechanism having an actuating member 32 which may be selectively engaged with the locking tabs 22 of the cart 10 to thereby move the locking tabs 22 to secure or release the drawers 16 of the cart 10 . In the exemplary embodiment shown, the actuating member 32 is provided with a cam surface 34 which engages the locking tab 22 . The actuating member 32 has a locked position wherein the cam surface 34 engages the locking tab 22 and moves the locking tab 22 to capture tines 36 of the drawers 16 with latches 38 coupled to the locking tab 22 . The actuating member 32 may be selectively moved to an unlocked position wherein the cam surface 34 disengages the drawer locking tab 22 to release the tines 36 from the latches 38 and thereby unlock the drawers 16 .
With continued reference to FIGS. 2 and 3 , and referring further to FIGS. 4A–4B , the actuating member 32 further includes a connecting arm 40 which is coupled to a manually actuated lock mechanism of the locking system. The manually actuated lock mechanism includes a lock core 42 which is slidably received in a first channel 44 in a lock housing 46 formed by first and second housing halves 46 a, 46 b secured by fasteners 47 , whereby movement of the lock core 42 within the lock housing 46 causes the actuating member 32 to move between the locked position (e.g. FIG. 4A ) and unlocked position (e.g. FIG. 5 ). A spring 48 disposed between the interior of the housing 46 and the lock core 42 , biases the lock core 42 in a direction toward the unlocked position of the actuating member 32 . A carriage bolt 50 installed through corresponding slots 52 a, 52 b formed in first and second halves 46 a, 46 b of the housing 46 extends through holes 54 , 56 formed in the lock core 42 and the connecting arm 40 , respectively, to thereby couple the actuating member 32 to the lock core 42 . The elongated slots 52 a, 52 b formed in the housing 46 also establish limits of travel for the actuating member 32 between the locked and unlocked positions.
The lock core 42 includes a selectively retractable lock pin 60 protruding from an upper surface of the lock core 42 . The lock pin 60 may be selectively caused to retract within the lock core 42 by manual manipulation of a key 62 inserted into a keyway 64 of the lock core 42 . In the first, locked position of the lock core 42 , the lock pin 60 engages a spring-biased lock catch 66 which protrudes into the first channel 44 (when not urged from the first channel 44 by the electronically actuated lock mechanism described below) to engage the pin 60 and thereby retain the lock core 42 in the first position as best depicted in FIGS. 7A and 7B . The lock catch 66 is biased to protrude into the first channel 44 by a second spring 68 disposed between the lock catch 66 and a retainer plate 70 secured to the housing 46 by a fastener 72 . When the key 62 is inserted into the keyway 64 and manipulated to retract the lock pin 60 , the lock core 42 is biased to the second, unlocked position by the first spring 48 disposed between the lock core 42 and an end wall of the housing 46 . As best illustrated with reference to FIGS. 4A and 5 , the first spring 48 is positioned over the connecting arm 40 and, because the actuating member 32 is coupled to the lock core 42 , the first spring 48 also biases the actuating member 32 toward the unlocked position ( FIGS. 7A–7B ) when the lock core 42 has been released from the lock catch 66 .
The locking system 12 further includes an electronically actuated lock mechanism configured to move the actuating member 32 between the locked and unlocked position without the need for a key 62 to manually operate the lock core 42 . In the exemplary embodiment shown, the electronically actuated lock mechanism includes a release member 80 slidably disposed within a second channel 82 formed between the first and second housing halves 46 a, 46 b. The release member 80 includes a release catch 84 having a first surface 86 configured to engage the lock pin 60 to thereby prevent the lock core 42 from moving in a direction toward the second, unlocked position relative to the release member 80 . A second surface 88 of the release catch 84 is inclined with respect to the lock pin 60 so that the lock pin 60 is caused to retract within the lock core 42 as the release member 80 is moved in a direction toward the second position of the lock core 42 to engage the second surface 88 of the release catch 84 with the lock pin 60 .
The electronically actuated lock mechanism further includes a drive motor 90 operatively coupled t 6 the release member 80 and actuable to move the release member 80 in a direction toward the second position of the lock core 42 or, alternatively, in a direction toward the first position of the lock core 42 . The drive motor 90 has an output shaft 92 coupled by coupling members 93 a, 93 b to a lead screw 94 that extends through the second channel 82 in the housing 46 to engage the release member 80 . Drive motor 90 is secured to the cart frame 20 by a mounting plate 89 and fasteners 91 a, 91 b. The release member 80 is formed with internal threads 96 which engage the lead screw 94 whereby rotation of the output shaft 92 in a first direction causes the release member 80 to move toward the second position of the lock core 42 . Likewise, rotation of the output shaft 92 in an opposite direction causes the release member 80 to move in a direction toward the first position of the lock core 42 .
The drive motor 90 is coupled by wires 98 to a power supply (not shown) and a control circuit 100 (see FIG. 2 ) of the medical cart 10 . When a user enters an appropriate access code via a keypad 102 , or other input device coupled to the control circuit 100 , the control circuit 100 energizes the drive motor 90 to move the release member 80 and thereby unlock or lock the cart 10 , as described more fully below. In the embodiment show in FIG. 2 , control circuit 100 is supported within the enclosure 14 by a support bracket 106 secured to frame 20 . A protective cover 108 may be provided on support bracket 108 to protect the control circuit 100 from moving components of the cart 10 .
A secondary control circuit 101 may be provided to receive input from the keypad 102 , or other user input device, and to communicate with control circuit 100 when a valid access code has been entered. While the user input device has been shown and described herein as a keypad 102 for entering an access code, it will be recognized that the input device may alternatively be a barcode scanner, a magnetic stripe reader, a device for verifying a bio-identification metric, or any other device suitable for receiving an input parameter and limiting access to the cart 10 .
Referring now to FIGS. 4A , 4 B, 5 , 6 A, 6 B and 7 A– 7 B, operation of the locking system 12 to selectively lock and unlock the drawers 16 of the medical cart 10 will now be described. FIGS. 4A–4B depict a locked condition of the cart 10 wherein the lock core 42 is in the first, locked position and the actuating member 32 is in the first position such that the cam surface 34 of the actuating member 32 engages the drawer tab 22 to cause the latch 38 on the drawer tab 22 to engage the tines 36 on the drawers 16 and thereby prevent opening of the drawers 16 .
In the exemplary embodiment depicted in FIGS. 4A–4B , the release member 80 is shown at its greatest extent of travel in the direction toward the first position of the lock core 42 such that the release catch 84 of the release member 80 engages the lock pin 60 and prevents movement of the lock core 42 toward the second, unlocked position. When the release member 80 is in this position, the release member 80 also displaces the spring-biased lock catch 66 and prevents the lock catch 66 from protruding into the first channel 44 of the housing 46 . Accordingly, the lock catch 66 normally protrudes into the first channel 44 of the housing 46 to engage the lock pin 60 when the lock core 42 is in the first position, as best depicted in FIGS. 7A–7B , but is displaced by the release member 80 to disengage the lock pin 60 and thereby permit the electronically actuated lock mechanism to move the lock core 42 between the first and second positions when the electronically actuated lock mechanism is actuated to lock and unlock the drawers 16 of the cart 10 , as will be described more fully below.
To manually unlock the drawers 16 of the cart 10 , the access key 62 is inserted into the keyway 64 of the lock core 42 and is actuated by rotating the key 62 to retract the lock pin 60 within the lock core 42 as best depicted with reference to FIGS. 4A and 5 . After the lock pin 60 is retracted into the lock core 42 , the lock core 42 is biased by the first spring 48 toward the second, unlocked position as depicted in FIG. 5 . As the lock core 42 moves toward the second position, the actuating member 32 moves toward the unlocked position whereby the cam surface 34 disengages the drawer tab 22 and the drawer tab 22 moves in an upward direction so that the latch 38 releases the drawer tine 36 thereby permitting the drawers 16 of the cart 10 to be freely opened.
When it is desired to subsequently lock the drawers 16 of the cart 10 after manually unlocking them, the lock core 42 may be moved from the second position to the first position by manually pushing the lock core 42 into the housing 46 to thereby engage the lock pin 60 with the release catch 84 in the first, locked position. The lock pin 60 is displaced by the sloped, second surface 88 of the release catch 84 as the lock core 42 is moved from the second position to the first position. After the lock pin 60 has passed the first surface 86 of the release catch 84 , the lock pin 60 snaps back into the extended position whereby the first surface 86 of the release catch 84 engages the lock pin 60 and prevents movement of the lock core 42 from the first position toward the second position.
Alternatively, the locking system 12 of the cart 10 may be operated by utilizing the electronically actuated lock mechanism. Operation of the locking system 12 in this mode may be advantageous, for example, when the key 62 for the locking system 12 is unavailable. With reference to FIGS. 4A–4B and 6 A– 6 B, the drawers 16 of the cart 10 may be unlocked when a user enters an appropriate access code into the keypad 102 , or other user input device, as described above. After the appropriate access code has been entered, and when the release member 80 is in the position depicted in FIGS. 4A–4B , the drive motor 90 is energized to cause the release member 80 to move in a direction toward the second position of the lock core 42 . Because the release member 80 displaces the lock catch 66 , as described above, the lock core 42 is biased by the first spring 48 to move with the release member 80 toward the second, unlocked position, as depicted in FIGS. 6A–6B .
When it is desired to re-lock the drawers 16 of the cart 10 , or when the control circuit 100 otherwise determines that the drawers 16 of the cart 10 should be locked, the drive motor 90 is energized to rotate the lead screw 94 in a direction to move the release member 80 in a direction toward the first position of the lock core 42 whereby the release catch 84 engaged with the lock pin 60 causes the lock core 42 to move from the second, unlocked position to the first, locked position, as depicted in FIGS. 4A–4B .
Alternatively, after the locking system 12 has been unlocked electronically, and is in the position illustrated in FIG. 6A–6B , the locking system 12 may be manually locked by manual displacement of the lock core 42 from the second position toward the first position. When the locking system 12 is operated in this manner to manually lock the cart 10 after being unlocked electronically, the lock pin 60 engages the lock catch 66 in the first position as depicted in FIGS. 7A–7B while the release member 80 remains in a position extended in a direction toward the second position of the lock core 42 . The lock pin 60 engages a sloped surface 104 on the lock catch 66 to thereby cause the lock catch 66 to retract from the first channel 48 and allow the lock core 42 to be moved to the first position. When the lock core 42 is in the first position, the lock catch 66 is biased back into the first channel 48 of the housing 46 by the second spring 68 to thereby engage the lock pin 60 and prevent movement of the lock core 42 from the first position toward the second position.
When the medical cart 10 has been locked manually after having been unlocked electronically, as described above and depicted in FIGS. 7A–7B , and it is subsequently desired to unlock the cart 10 electronically, it will be recognized that the control circuit 100 must first energize the drive motor 90 to cause the release member 80 to move in a direction toward the first, locked position of the lock core 42 to thereby disengage the lock catch 66 . In an exemplary embodiment, control circuit 100 will automatically cause the release member 80 to return to the first, locked position of the lock core 42 when the cart is manually locked after having been unlocked electronically. Subsequently, the control circuit 100 is energized the drive motor 90 to cause the release member 80 to move in a direction toward the second, unlocked position of the lock core 42 , as described above with respect to FIGS. 4A–4B and 6 A– 6 B.
The locking system 12 of the present invention may therefore be operated to lock and unlock the drawers 16 of the medical cart 10 either electronically or manually as described above. Advantageously, the locking system 12 of the present invention permits users to selectively lock or unlock the drawers 16 of the cart 10 manually or electronically, regardless of whether the drawers 16 have been previously locked or unlocked either manually or electronically. To facilitate the proper operation of the cart 10 , the locking system 12 further includes sensors configured to detect the various conditions of the locking system 12 . In the exemplary embodiment shown, the locking system 12 includes a first sensor 110 to detect whether the lock core 42 is in the first, locked position. In this embodiment, the first sensor 110 comprises a switch that is actuated by the carriage bolt 50 that couples the actuating member 32 to the lock core 42 and which extends through the slots 52 a, 52 b formed in the first and second housing halves 46 a, 46 b.
In another embodiment, the locking system 12 further includes second and third sensors 112 , 114 configured to determine when the release member 80 has reached desired limits of travel in both the direction toward the first position of the lock core 42 and in the direction toward the second position of the lock core 42 . In the exemplary embodiment shown, the second and third sensors 112 , 114 comprise optical sensors positioned within the housing 46 to detect when the release member 80 has reached the respective limits of travel. The first, second, and third sensors 110 , 112 , 114 are mounted to a circuit board 116 and communicate with the control circuit 100 . A conductive member 118 is attached to the housing 46 and is operatively coupled to the cart frame 20 , such as by contact with a fastener 120 , to dissipate static electricity from the housing 46 and thereby protect sensors 110 , 112 , 114 and circuit board 116 .
The sensors 110 , 112 , 114 provide signals to the control circuit 100 which are used by the control circuit 100 to determine when the drive motor 90 should be de-energized to stop the release member 80 at the respective limits of travel, and to determine when the release member 80 must be moved toward the first position to disengage the lock catch 66 and thereby unlock the system 12 electronically subsequent to manual locking of the system 12 , as described above.
While the present invention has been illustrated by the description of an embodiment thereof, and while the embodiment has been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of the general inventive concept. | A locking system for a cart having at least one drawer movable between an open position and a closed position. The locking system includes a cam that is movable between a locked position, wherein the drawer of the cart is prevented from moving between the closed and open positions, and an unlocked position, wherein the drawer is released for movement between the closed and open positions. A manually actuated lock mechanism is coupled to the cam and is operable to move the cam between the locked and unlocked positions. An electronically actuated lock mechanism cooperates with the manually actuated lock mechanism to permit automatic operation of the locking system. | 4 |
BACKGROUND OF THE INVENTION
The present invention describes devices which rely on the purely microscopic quantum-mechanical phenomenon of exchange coupling between the spins of moving and bound electrons in a ferromagnet. The exploitation of exchange coupling in these devices makes possible unprecedented advances in speed and density in data storage and active integrated digital circuitry.
In contrast to the present invention, present-day applications of magnetism generally rely on macroscopic or mesoscopic magnetic phenomena. These phenomena depend on conventional magnetic concepts including B-H characteristics, permeability, coercivity, gyromagnetic ratio, magnetic domains and the like. Typically, the electric current in a wire induces a magnetic field and then the magnetic field acts on a ferromagnetic body in order to create the desired effect. Upon this conceptual framework rests the engineering of electric motors, bubble storage, and other magnetic devices.
SUMMARY OF THE INVENTION
This invention provides new means of dynamically remagnetizing or magnetically exciting a very thin ferromagnetic film, without the use of an externally applied magnetic field. In the present invention, electrons flow through a free or excitable magnet, or reflect from it, to make its magnetization respond. To accomplish this, the spin vectors of the flowing electrons must be preferentially polarized by an auxiliary ferromagnet, whose moment orientation is fixed by provided means. The electrons flow between the fixed and free ferromagnets through a non-magnetic metallic spacer which is thick enough to make the static inter-magnetic exchange coupling negligible. While transmitting thru or reflecting from the free ferromagnet, the spins of the moving electrons interact by quantum-mechanical exchange with the local, permanently present, spontaneously-polarized electron spins of the free magnet. This interaction causes a transfer of vectorial angular momentum between the several metallic layers in the device which causes the magnetization vector of the free magnet to change its direction continually with time. Thus excited, the magnetization vector will precess about its original axis. The precession cone angle will either attain a new equilibrium value which will be sustained by the current or will increase beyond 90° and precess with decreasing amplitude until the magnetization vector has reversed by 180° from its initial direction (i.e., switched). This form of magnetic excitation is called spin transfer. There are two modes of spin transfer, transmission and reflection, each having its preferred uses.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will be apparent from the following description taken in connection with the accompanying drawings, wherein:
FIG. 1 is a schematic of an elementary five layer device of the invention illustrating spin transfer by electron transmission;
FIG. 2 is a graph of rotation rate of the magnetization vector of the free-magnet region (F2) of the device of FIG. 1 vs. the instantaneous angle θ(t) for various values of the polarization factor P;
FIG. 3 is a schematic of a write only device employing the principle of spin transfer by electron transmission wherein the polarizer F1 is on the disk;
FIG. 4 is a schematic of a write only device employing the principle of spin transfer by electron transmission wherein the polarizer is on the stylus;
FIG. 5 is a schematic of an elementary device of the invention illustrating spin transfer by electron reflection;
FIG. 6 is a cross-sectional view of a three terminal device based on reflection-mode spin transfer;
FIG. 7 is a top (plan) view of the device of FIG. 6 including a schematic of associated circuitry for latch function;
FIG. 8A is a graph of current versus time for input current pulses applied to the device of FIG. 7;
FIG. 8B is a graph of the precession-cone angle θ(t) as a function of time for the device of FIG. 7 in response to the input current pulses of FIG. 8A;
FIG. 8C is a graph of the voltage V L across the load of the device of FIG. 7 as a function of time;
FIG. 9A is a graph of the configuration of the device of FIG. 6 which functions as a latch unit;
FIG. 9B is a graph of the configuration of the device of FIG. 6 which functions as an oscillator;
FIG. 9C is a graph of the configuration of the device of FIG. 6 which functions as a preamplifier.
DETAILED DESCRIPTION OF THE INVENTION
It is a fundamental fact that the macroscopic magnetization intensity of a magnet such as iron arises from the cooperative mutual alignment of elementary magnetic moments carried by electrons. An electron is little more than a mass particle carrying an electrostatic charge which spins at a constant rate, like a planet about its axis. The electric current of this spin induces a surrounding magnetic field distribution resembling that which surrounds the Earth. Thus, each electron is effectively a miniscule permanent magnet. An ordinary permanent bar magnet, such as Alnico, consists of a collection of such microscopic magnets, electrostatically bound to the atoms, which are mutually aligned to provide the spontaneous polarization whose intensity and direction are measured by the macroscopic magnetization vector.
The exchange interaction is that force, arising quantum-mechanically from electrostatic interactions between spinning electrons, which causes this mutual alignment. Most quantum effects, such as electron momentum, have classical macroscopic counterparts in accord with the general Correspondence Principle. Exchange interaction is the one exception which has no classical counterpart. Not only does it couple the bound spins of a ferromagnet to each other, but it also couples the spins of moving electrons, such as those partaking in current flow, to these bound electrons. The present invention involves the novel use of the latter moving electron to bound electron exchange coupling to induce useful changes of magnetic state or magnetic excitation.
In the pentalayer device 10 of layer composition A/F1/B/F2/C of FIG. 1, all 5 regions are metals or are otherwise good conductors of electricity. Regions A, B, and C are non-magnetic metals, e.g. gold or copper. Region F1 contains a fixed magnet (spin polarizer). The magnet of region F1 may be a two-layer composite of an anti-ferromagnetic sublayer such as MnFe for exchange bias plus a polarizing sublayer of a good ferromagnetic or ferrimagnetic metal, such as Fe, Co, or Ni, or alloys including these elements. Or else, F 1 may be a single-layer metallic permanent-magnetic material such as BiMn, Alnico, or RCo 5 (R=Y, La, Pr, Nd, or Sm). Herein, the term magnet or magnetic will embrace both ferromagnetism and ferrimagnetism. The free-magnet region F2 will have one of numerous magnetic compositions to be specified below according to the nature of the application. Its macroscopic magnetization vector will be freer either because it lacks antiferromagnetic bias, has weaker anisotropy, has a smaller loss parameter, has a lesser thickness, or as a result of a combination of these factors. The directions of easy magnetization required in the layers F1 and F2 will also depend on the use to which the device is put as is explained in greater detail below.
It is known from electron-transmission experiments that the spins of an electron stream transmitted through a magnetic film become partially spin-polarized, as described by Lassailly, et al. in Phys. Rev. B, 50 (1994), which is herein incorporated by reference. Therefore, the spin vectors of electrons driven rightward (from layer A to layer C) through the pentalayer perpendicular to interfaces 12 between the layers by an imposed current are preferentially polarized, usually in the direction (-M 1 ), after passing rightward through the fixed magnet F1 into layer B in FIG. 1. The existence of spin-polarized electron-wave states and currents within non-magnetic spacers of magnetic multilayers similar to the pentalayer is known experimentally from inverse photo-electric measurements, the observation of oscillatory exchange coupling, and measurements of the so-called giant magnetoresistance (GMR), as described by Fert, et al., J. Magn. Magn. Mater., V140 (1995) p.1, which is incorporated herein by reference. Each of these effects depends on the presence of spin-dependent wave scattering at interfaces within the multilayer. The occurrence of these spin-dependent scatterings at the interfaces is a precondition for the present invention. Their experimental existence constitutes proof of its feasibility.
To-and-fro motions of thermally-equilibrated spin-polarized electrons through a non-magnetic spacer cause the well-known oscillations of conventional inter-magnetic exchange coupling versus spacer thickness in the absence of net current. It follows that an externally imposed flow of electric current causes a dynamic exchange of angular momentum between the two spin reservoirs contained in the two magnets.
The effect of this dynamic spin transfer is to cause the free moment M 2 (t) to rotate within the instantaneous plane determined by M 2 and the fixed M 1 . The rotation rate dθ/dt versus the instantaneous angle θ shown in FIG. 1 is plotted in FIG. 2 for various values of the polarization factor P pertaining to the magnets (assumed alike). Their rate is calculated in the well-known Wentzel-Kramers-Brillouin (WKB) approximation of the Schroedinger wave equation for electron dynamics. The units for the vertical axis of FIG. 2 are I/eN 2 where I is the current, e is the electron charge, and N 2 is the total number of uncompensated localized electron spins forming the spontaneous moment of the free magnet F2.
The physical meaning of FIG. 2, in essence, is that the passage of each spin-polarized electron rotates the spin momentum vector of the free magnet by one quantum unit in order of magnitude. The rotation vanishes at angles θ=0 or π, for which the component of transferred spin oriented orthogonal to the free moment vanishes. If P is small, or if the electron scattering in not coherent as assumed in the WKB approximation, the function plotted in FIG. 2 tends to a constant times sin θ.
The polarization factor, P, of a ferromagnet is a characteristic of the small number of electrons which are available for movement (in an electrical current) through the ferromagnetic body, namely those near the Fermi level which is the highest energy level occupied by any electron at absolute T=0°. At T>0, the occupation probability at the Fermi level is 50%. Of these electrons, the density of those whose spin direction agrees with that of the majority is written n + . Likewise, the density of those electrons whose spin direction is opposed to the majority is n - . P is the ratio of the net spin of these electrons pointing in the majority direction to the total, i.e., P=(n + -n - )/(n + +n - ).
Measured values of the polarization parameter P, which appears in FIG. 2, are given for several magnetic compositions in Table I below:
TABLE I______________________________________compos.: CrO.sub.2 Fe CO Ni80Fe20 Ni Gd______________________________________P= ≃1.0 0.40 0.35 0.30 0.23 0.14______________________________________
The value P≅1.0 listed above for CrO 2 , which is metallic for but one spin direction, was measured by photoemission. The remaining values in the table were determined by tunneling to superconductors. The polarization satisfies |P|<1 whenever energy bands for both signs of spin are metallic. Although the polarizations of NiMnSb and magnetite (Fe 3 O 4 ) have not been measured, theoretically they should also be nearly 1 because they are both half-metallic magnets.
If M 2 is initially nearly parallel to M 1 , then a current I having the correct sign so as to flow electrons from layer C to layer A perpendicular to the interfaces 12 between the layers will cause θ to increase with time at a rate predicted in FIG. 2. Other, passive energy-conserving effects such as local and shape-determined magnetic anisotropy energies, generally cause a rapid quasi-conical precession of the tip of vector M 2 about the axis of anisotropy. But switching, described by an increase of the cone angle, θ, to the neighborhood of π, will occur if the current-imposed contribution to the cone-angle rate dθ/dt exceeds in magnitude the negative contribution due to the well-known spin-lattice relaxation and other loss mechanisms.
Reversing the sign of the current I will reverse the sign of the units of the vertical axis in FIG. 2, thus reversing the direction of this switching. However, as seen in FIG. 2, the switching effect is generally not symmetric geometrically. It is stronger per unit current near θ=π than θ=0 because the passage of electrons having both signs of spin tends to be blocked when the magnets are nearly opposed to each other. Also, according to FIG. 2, switching cannot occur mathematically if the exact condition θ=0 or π holds initially, for then dθ/dt=0. However, in practice considerable misalignments of crystal axes or thermal fluctuations will insure sufficient departures from this condition for switching to occur.
In the transmission mode of operation, the thickness W B of sublayer B must be less than the characteristic spin-diffusion distance λ sd otherwise the spin polarization of the conduction electrons will decay before they transit between the ferromagnets. This upper bound distance is believed to vary between about λ sd =100 nm and about λ sd =1000 nm depending on the composition of layer B. On the other hand, the thickness of B must be large enough to prevent the ordinary exchange coupling between F1 and F2 from interfering with operation of the device. For many spacer compositions, a lower bound thickness greater than about 3 nm will satisfy this condition.
The principle of the invention described above is particularly suitable to the application of writing on a disk. In this case, the usual inductive write head is replaced with an electric stylus. The magnetization direction in the recorded pattern may be either parallel or perpendicular to the media plane. FIGS. 3 and 4 illustrate only the parallel case. There are two alternative device configurations for each case, i.e., the polarizer on the disk and the polarizer on the stylus.
FIG. 3 is for the case of the polarizer on the disk and shows a section of the layers A, F1, B, and F2 integrated on the disk. (Throughout this description, the notations A,B,C,F1,F2 in all figures are consistent with those in FIG. 1. The drawings are not to scale.) The reorientable layer F2 may be ordinary film recording media (e.g., CrO 2 , Fe 3 O 4 ) with consideration given to the measurable polarization factors P such as those of Table I to optimize spin-transfer efficiency. Region C is part of a stylus (shown in 3D projection), whose shape resembles the blade of a common screw driver, serving in place of the usual inductive write head. Its structure may vary, but in this example it has a solid shank portion of a non-magnetic conductor terminating in a wedge-shaped structure having shielding material (e.g., a NiFe alloy) on both elongated faces of the wedge-shaped structure. It makes sliding contact with F2 preferably through a layer of material, L, which facilitates the sliding contact such as, an ≅3 nm-thick film of metallic lubricant, such as mercury. Horizontal arrows shown in layer F2 indicate the data recorded digitally by pulses of current I while the media moves horizontally with respect to the stylus. The slanted Ni--Fe shield S shown fore and aft of C prevents disturbance of this recorded trace by the magnetic field induced by the pulsed write current I flowing vertically through the entire assembly. The dashed curves indicate the pattern of this current flow.
FIG. 4 is for the case of the polarizer on the stylus. Here, the device is inverted; only the layer F2 containing storage cells and the connector layer C are integrated on the disk. The storage layer makes sliding contact through layer B to the stylus which contains regions A and F1. Here, layer B may also be the lubricating layer L or L may be placed on top of layer B. The two magnetic shields marked S again function as previously. For the shield to function, the polarizer F1 on the stylus must be separated from the shield S by an insulating layer (not shown), e.g. Al 2 O 3 , SiO, or MgO, with thickness about 5 or 10 nm, which will serve to prevent conventional exchange coupling between F1 and S.
These novel devices exhibit very low power consumption and considerable device efficiency with acceptable heating over small distance scales. If the effective thickness of the layer with appreciable Ohmic dissipation is assumed to be 10 w where w is the F2 media thickness, the total power per unit area of storage cell, writing at some hundreds of MHz bit rate, is estimated by:
φ=40w.sup.3 ρ(eM.sub.s2 /βτ').sup.2 (P.sub.1 P.sub.2).sup.-3 (1)
where ρ is the mean resistivity of the multilayer, e is the electron charge, β is the Bohr magneton of the electron, P 1 and P 2 are the polarization factors, and M s2 is the spontaneous magnetization of magnet F2. The variable τ' is defined by τ'=(2 πΔν+τ -1 ) -1 , where Δν is the ferromagnetic-resonance linewidth, and τ is the pulse width. For ρ=10 3 μΩcm, τ'=1 ns, w=4 nm, and M s2 =10 3 G and P 1 =P 2 =1, the power is about 10 mW/μm 2 for one storage cell. The form of this relation implies the existence of threshold current and power, corresponding to τ=∞, below which switching will not occur.
The amplitude j of the current pulse per unit of device area required for switching is estimated by:
j=2ewM.sub.s2 /βτ'(P.sub.1 P.sub.2).sup.-3/2 (1A)
Assuming the same parameter values substituted above in Eqn. (1), the current density j=200 mA/μm 2 within the addressed storage cell.
Thus, not only is the expected power requirement of the spin-transfer write device tiny, but, if the polarizer is on the disk, most of the power is distributed over the bulky disk instead of being concentrated in the small write head. Also, the low duty cycle of a given storage location in the media implies a minimum of electromigration in spite of the large (≅10 7 Acm -2 ) current densities flowing. The ≅1mJcm -2 energy dissipated on the disk during one write operation is much too small to ablate the surface.
Placing the polarizer on the stylus causes much of the power to be dissipated there, but it has the complementary advantage of cost savings in the fabrication of a simpler disk. Apart from replacement of a conventional inductive write head, spin transfer by transmission will be suitable for implementing, in connection with storage devices, techniques using rotational or raster scanning with very finely pointed probes.
The device is restructured as shown in FIG. 5 for operation in the reflection mode. The main difference is that now the connecting (contact) region C contacts the spacer B instead of magnet F2. Region C, which may be an extension of region B, is positioned to the sides in order to receive many of the electrons scattered from F2. (Aside from this change, the sequential layer notation A, F1, B, F2, C appearing in FIG. 5 follows the pattern established in FIG. 1.) Instead of the spin-polarized current flowing through a remagnetizable magnetic film F2, the presence of air or other insulator above it insures that most of it must now reflect from F2. The electron-exchange coupling involved in this reflection process transfers a part of the spin-angular momentum of the moving electrons to the magnet F2. The macroscopic effect of this spin transfer is again to excite the quasi-conical precession of the magnetization vector M 2 and dynamically vary the angle θ of this precession cone.
In the case of the switching operation in a memory cell or latch device, a current pulse I is supplied externally as indicated in FIG. 5. The rate of reversal of moment M 2 is again optimally on the order of one electron spin for each electron that flows through the input circuit from terminal A to terminal C. Realistically, this rate is diminished by three factors: 1) the less-than perfect polarizing power P 1 of the fixed magnet F1, 2) the probability p that an electron passing through F1 will, upon passing ballistically through the copper spacer B, impact on the switching magnet F2 and then scatter out of the device core into terminal C, and 3) the imperfect polarizing power P 2 of F2. The vertical dimension and one of the other dimensions of the spacer B should not be much greater than the mean free path, λ, of an electron, about 30 nm. This allows the electron dynamics of current flow to be substantially ballistic so that a large fraction of the flowing electrons scatters from F2. The epitaxial deposition specified below will insure that λ is near 300 Å for the preferred elemental spacer compositions Cu, Au, Ag and Al. Generally, the thickness of this layer should be in the range of about 3 nm to about 50 nm.
Two illustrative dashed electron-wave trajectories, labeled #1 and #2, are shown in FIG. 5. Trajectory #1, having velocity v, begins in the non-magnetic connector region A with spin s oriented up or down with equal probabilities. Then magnet F1 splits it into a reflected predominantly spin-up wave plus a transmitted wave with spin-down predominating to the degree P 1 . Magnet F2, whose time-dependent moment M 2 , forms angle θ(t) with M 1 held vertically by anisotropy, reflects or scatters the mostly spin-down electron wave downward with 100% probability because of the air or other insulator lying above it. The largest possible upward vectorial change of s due to this scattering event has the magnitude of the Planck constant h. The consequent recoil on M 2 is limited to |δM 2 |wd 2 ≦β where d is the diameter of region F2, w is its thickness, and β is the Bohr magneton. More precisely, the corresponding change in θ due to scattering of one electron is Δθ=-(βP 2 /M S2 wd 2 ) sin θ, where the polarization coefficient P 2 measures the efficiency of this transfer. The factor sin θ in this relation implies that this switching process is more nearly symmetric between the θ=0 and π orientations, unlike FIG. 2 which shows a skew towards θ/π=1.0. The electron proceeds along trajectory #1 in its altered spin state to the terminal region C to complete the electric circuit. Alternatively, the electron might take a course like path #2 which does not strike F2 and leaves M 2 unaffected. Hence the relevant probability coefficient p satisfies p<1. The result is that the current I<0 causes switching from θ≅π to θ≅π by creating a long series of such small changes Δθ.
When the sign of the current is positive (current flow from A to C), an unpolarized electron entering B from terminal C may partially reflect upward from F1 carrying predominantly up spin, thus causing Δθ>0 when it subsequently reflects from F2, with its spin now flipped to the down direction. Such spin down electrons pass more readily thru F2, closing the current circuit for this direction of current flow. The result is that a current satisfying I>0 causes switching from θ≅0 to θ≅π.
As before, using τ'=(τ -1 +2πΔν) -1 , and assuming that the polarization coefficients P 1 , P 2 , and the ballistic efficiency p enter inversely into the required switching current, it is possible to estimate the switching current for the switching time τ for θ to vary between the neighborhood of 0 to that of π. This results in:
I.sub.s =2eM.sub.s2 d.sup.2 w/βτ'P.sub.1 P.sub.2 p(2)
where e is the electron charge, M s2 is the spontaneous magnetization of magnet F2, d is the diameter of the device column, w is the thickness of layer F2 and β is the Bohr magneton. With M s2 =200 G, d=30 nm, w=1 nm, τ'=1 ns, P 1 =P 2 =0.35 and p=0.4, the switching current I s =200 μA. The advantage of using small-moment (M s2 ) compositions for magnet F2 is clear. The threshold current for switching is estimated by this equation with the special value τ=∞.
Since the circuit resistance is considered to be dominated by the ballistic resistance with a mean transmissivity T between terminals A and C shown in FIG. 5, the energy dissipated in one switch, well above threshold, is estimated by
E.sub.s -(12π/τT)(dwM.sub.s2 /k.sub.F βP.sub.1 P.sub.2 p).sup.2(3)
Substituting the same parameter values as above for Eqn. (2), the switching energy E s 1×10 -16 Joule. This predicted trade-off between switching time and energy is competitive with that of advanced semiconductor devices. At the same time, Eq. (3) indicates a considerable latitude for further improvement by optimization of material and dimensional parameters.
Considering the current density j=2×10 7 A/cm 2 passing through F1 using the nominal parameter values of Eq. (2), electromigration is a concern at ambient temperature. Long-lived ambient-temperature devices are obtainable by 1) avoiding grain boundaries through growing layers and contacts epitaxially, 2) developing higher-polarization magnets with low M s , and 3) making the electrical connectors of gold, which is known to be highly resistant to electromigration.
The low energy dissipated in the devices of the present invention is in contrast to the large energy expended in the spin transfer thru a tunnel barrier, termed therein "dissipative exchange coupling", described by Slonczewski in Phys. Rev. B, vol. 39 (1989), p.6995. The rate of spin transfer is principally governed by the current I. Since the dissipated power is given by Φ=I 2 R, and I is about the same for a given rate of spin transfer, it follows that the resistance R of the spacer principally governs the power dissipated. But in quantum transport, R∝T -1 where T is the mean transmission coefficient of an electron passing through the multilayer device. In the case where the spacer is metallic, T m is estimated conservatively as ≈10 -1 . However, if the spacer is a barrier of thickness D such as Al 2 O 3 , then T b ≈exp(-2 kD), where k is the imaginary momentum which measures the size of the potential barrier, and D is the barrier thickness. In practice, the thickness must satisfy D > .sup.˜ 1 nm otherwise accidental bridges of magnetic material fill the "pinholes" in the barrier, creating a conventional exchange coupling between F1 and F2 which interferes with the operation of this invention. Since k=10 nm -1 , typically T b ≦.sup.˜ exp (-20)≈10 -6 and the power Φ is T m /T b =10 5 times greater in the case of a magnetic tunneling junction. Therefore, the effect described in the above reference would not be practiced in any of the devices made possible by the present invention.
FIGS. 6 and 7 show cross-sectional and plan views of a 3-terminal device which illustrates uses of reflection-mode spin transfer. Depending on the nature of the connected circuitry and the orientations and strengths of magnetic anisotropy in the magnetic regions F1, F2, and F3, the device of FIG. 6 may serve as a memory cell, latch, logic gate, ac oscillator, or ac preamplifier.
The cross-section in FIG. 6 shows two partly overlapping stages of which the lower stage is the present invention shown in FIG. 5, and the upper stage is a magnetic valve of either the tunneling type (MTV) whose spacer is an insulating barrier such as is described by Miyazaki and Tezuka in J. Magn. and Magn. Mats., 139 (1995) L231, which is herein incorporated by reference, or the so-called CPP GMR type whose spacer is metallic as described by Pratt, et al., J. Magn. Magn. Mater., 126 (1993), p406, which is also incorporated herein by reference. This valve structure includes conducting layer B and magnet F2 of the lower stage.
It has three more layers in addition. Layer D, lying on top of F2 is an insulating tunnel barrier such as Al 2 O 3 or one of a number of non-magnetic metals providing the so-called CPP-GMR magnetoresistive effect. Aside from providing the valve effect itself, the main requirement of this spacer is that its resistance is sufficient to limit the current during valve operation to a value well below the threshold for the switching action of the sort occurring in the spin-transfer stage. Layer F3, lying on top of D, is a fixed metallic magnet similar to F1, with its moment M 3 also permanently magnetized vertically.
Layer E is an electric connector such as Au or Cu. The performance of MTV and GMR valves is well-established by experiments. In essence, magnet F3 behaves as a spin-analyzer of the electrons passing through magnet F2 and spacer D. The conductance of the valve stage varies as G=G 0 (1+ε cos θ). Experiments demonstrate reproducible efficiencies exceeding 2ε=10% at ambient temperature.
FIG. 7 shows a plan view of the 3-terminal device on a finer scale. The circular (or square or other symmetric or asymmetric configuration) of the tower having diameter d in FIG. 6 appears only as a small circle in FIG. 7. Alternatively, the cross-section may be oblong, in which case d is the smaller in-plane dimension. A larger scale of lithography defines the external portions of the metallization for the three leads comprising terminals (or contacts or connecting regions) A, C and E, only small parts of which appear in FIG. 6. Each of the three terminals has the shape of a rectangular wire one of whose ends overlaps one end of each of the others and the two insulators within the square region seen in FIG. 7.
Of the several types of device based on reflection-mode spin transfer using the structure of FIG. 6 and described later, the electronic circuit shown schematically in FIG. 7 illustrates the latch. It works in time as shown in FIG. 8. At time t 1 , an input signal stimulates the 2 mV supply to produce a τ=1 ns wide pulse in the input subcircuit causing a 200 μA current pulse to flow between terminals A and C. During this switching time τ, electrons polarized by magnet F1 flow through the "exchange chamber" B and effect the increase of the precession-cone angle θ(t) of the moment M 2 (t) θ≅0 to nearly π. (This moment M 2 is meanwhile pseudo-Larmor processing about the film normal under the influence of the uniaxial anisotropy at a variable rate generally greater than τ -1 .) In the meanwhile, this change of θ causes ≅10% net increase in the tunnel resistance of layer D, in accordance with the well-established MTV effect. As a result, the voltage V L across the load decreases from 100 nm by 5 mV; the sense circuit senses this signal and passes it to the next stage of a network (not shown). A subsequent pulse of reversed sign at time t 2 in FIG. 8 restores the original direction of M 2 and therefore the initial 100 mV level of the output signal.
The operation described constitutes a latch circuit. Equation (2) implies that there is a current threshold below which switching will not occur. Therefore, inputs can be combined in digital fashion to use this form of the device to provide memory and logic operations including devices such as AND gates.
The easy uniaxial anisotropy energy K U2 of F2 must be sufficiently strong to block reversal of M 2 through thermally excited domain wall motion according to the inequality
d>25k.sub.b T/wA.sub.2.sup.1/2 (K.sub.μ2 -2πM.sub.s2.sup.2).sup.1/2(3A)
where T is the absolute temperature, k B is Boltzmann's constant, and A 2 is the exchange stiffness of F2. Substituting T=300K, w=1 nm, A 2 =10 -6 erg cm -1 , K.sub.μ2 -2πM s2 2 =10 8 erg cm -3 , the diameter d must exceed 10 nm for thermal stability of the stored bit and the magnetization M S2 must be small to keep the switching current (2) small.
The 3-terminal reflective-spin-transfer device shown in FIGS. 6 and 7 has various uses requiring different circuit characteristics and combinations of magnetic parameters and preferred-axis orientations. The magnetic geometries for the three uses are shown schematically in FIG. 9. They are a) memory or latch (discussed above), b) oscillator, and c) analog preamplifier. The descriptions and specifications are as follows.
For the memory, latch or logic gate of FIG. 9A, the preferred axes of the 3 magnets F1, F2, and F3 are all "vertical" (i.e., in the same direction or orientation) as discussed above. Other orientations can serve as long as they are parallel to the same axis.
For the tunable oscillator of FIG. 9B, the oscillations are obtained from the steady precession of M 2 at some frequency ν within the midplane of the film. That is, the precession cone with θ having a constant value near 90° degenerates to nearly plane. To stabilize this in-plane orientation, the combination of demagnetization and uniaxial material anisotropy H U2 (=2K U2 /M S2 ) must be negative. Either one of two conditions must be satisfied: B S2 -H U2 >>2πν/γ, or a vertical external magnetic field H DC =2πν/γ is needed as provided by, for example, a permanent magnet (not shown in FIG. 9B).
In the former case, one may use iron for F2, for which the experimental loss parameter is α=3×10 -3 . For the vertically magnetized polarizer F1, one may again use epitaxial RCo 5 as in the memory cell above.
The input current, of density j, energizes the precession, whose frequency is tuned by simple proportion to j, for j exceeding some threshold depending on the strength of in-plane anisotropy. Above this threshold, the frequency is given by:
ν=jP.sub.1 P.sub.2 p/eαM.sub.S2 w (4)
where P 1 and P 2 are polarization factors such as those in Table I, p is the probability of an incident electron closing the circuit, α is the Gilbert damping constant, M s2 is the spontaneous magnetization of magnet F2, and w is the thickness of layer F2. Substituting j=10 7 Acm -2 , P 1 =0.3, P 2 =0.4, ρ=0.4, α=3×10 -3 , M s2 =1700 G, and w=1 nm, the oscillator frequency ν=10 GHz. The fixed direction of M 3 in F3 is now horizontal in FIG. 9B, so that the output voltage becomes proportional to the corresponding component of the processing M 2 . The layer F3 may be iron with an overlayer of MnFe to permanently fix the magnetization direction.
In the preamplifier of FIG. 9C, the input voltage carries an AC input signal with frequency ν. Essential are the conditions that M 1 is parallel to ±M 3 and that the direction of M 2 at rest is orthogonal to M 1 and M 3 . This geometry maximizes the angular velocity |dθ/dt| and the output signal. Thus, M 2 oscillates in one plane about a mean direction orthogonal to M 1 and M 3 . The oscillation plane for M 2 contains M 1 and M 3 . In other respects, the orientations are a matter of practical convenience.
An example of a feasible fabrication procedure for the devices of this invention, here particularly the device structure of FIG. 6 having magnetic geometries and functions of FIG. 9 follows. For layers A, F1, and B, it utilizes when possible epitaxial evaporation common for (111) Cu/Co and Au/Co multilayers, and/or epitaxial sputtering used for (111) orientations of Cu, Co, Ni, or Ag. Epitaxy insures the ballistic electron motion needed in layer B. The procedure is:
1. Begin with a (011) GaAs (for evaporation) or Al 2 O 3 (0001) (for sputtering) substrate.
2. Deposit, without masking, the sequence of layers comprising the central column of the device shown in FIG. 6;
a. Layer A: Epitaxial copper or gold.
b. Layer Fi: About 5 nm of permanently magnetized epitaxial hexagonal high-moment RCo 5 . (R=Sm, Y, La, Pr, or Nd) for latch (a) or oscillator (b). For preamplifier (c), CrO 2 , NiMnSb or Fe/MnFe bilayer, without epitaxy, may be used.
c. Layer B: About 20 nm of gold or copper to serve as the "ballistic chamber" for spin exchange between F1 and F2. This layer should be epitaxial for the memory or oscillator and will be non-epitaxial for the preamplifier.
d. Layer F2: For the memory device, about 1 nm, but not more than about 10 nm of the free epitaxial low-moment R'Co 5 where R'=Gd,Tb, or Dy. For the oscillator, Fe, which has the nominal parameters of Eqn. (4), is used. For the preamplifier, one of many compositions of Gd--Co--Mo amorphous-bubble material giving vertical orientation is used.
e. Layer D: About 1 or 2 nm of alumina, Al 2 O 3 or other non-magnetic insulator. The thickness of this layer is adjusted to obtain desired tunneling resistance for MTV operation in the output circuit.
The remaining depositions will not be epitaxial.
f. Layer F3: About 5 nm of permanently magnetized RCo 5 is used for the memory device. For the oscillator, the bilayer Fe/MnFe is used to obtain in-plane orientation and for the preamplifier, the same material as was used in layer F1 is used.
g. Layer E: About 30 nm gold or copper for the electrodes.
Deposition of the 3 magnetic layers described above requires:
a. Low substrate temperature to prevent decomposition of RCo 5 and R'Co.sub. 5 .
b. Maintenance of a magnetic field during deposition of fixed magnetic layers F1 and F3 to predetermine the static magnetization directions in accordance with the device functions indicated in FIG. 9.
3. By means of e-beam or x-ray lithography, define the column.
4. Etch or ion mill away material surrounding the column to a depth of about 10 mn below the bottom of F1.
5. A coarser scale lithography and registration (e. g. 1 μm) is used to define the lead wires shown in the plan view of FIG. 7. An insulating layer, 15 nm of copper connector C, a second insulating layer, and (after planarization) a thicker copper connector E are deposited in succession. (Several nanometers of tolerance are present in the vertical positioning of the four horizontal interfaces of the insulators.) Following each deposition of insulation and of connector E, the small amount of unwanted material which was deposited on the vertical sides of the central column must be dissolved or etched away.
In case the magnetic materials have tetragonal crystalline symmetry, a (100) GaAs substrate is required instead of (011), and fourfold crystallinity or texture must be maintained during the multilayer deposition of the spin-transfer stage.
For the preamplifier wherein M 1 and M 3 lie in the film plane, epitaxy is not absolutely necessary because there is no threshold of current for operation of an analog device. Field-deposited CrO 2 or Fe/MnFe bilayers may be used for layers F1 and F3. The vertical orientation of the mean M 2 is obtained by sputtering one of many compositions of Gd--Co--Mo amorphous-bubble material well-known in magnetic bubble device technology. The main restriction is 0<H U2 -B s2 <2πν/γ, which guarantees vertical orientation of M 2 at rest, and that precession does not interfere with the amplification mechanism. The voltage-gain-frequency product is estimated as
Gν=eβk.sub.F.sup.2 V.sub.B TP.sub.1 P.sub.2.sup.2 P.sub.3 p/8π.sup.3 M.sub.s2 w (5)
where G is the voltage gain, ν is the signal frequency, e is the electron charge, k F is the Fermi wave vector (estimated as 10 nm -1 ), V B is the barrier voltage in the output circuit, T is the mean electron transmission coefficient in the input circuit, P 1 , P 2 , P 3 are the polarization factor for respective magnets F1, F2, F3, p is the probability of ballistic electron reflecting from F2, h is Planck's constant, M s2 is the spontaneous magnetization of F2 and w is the thickness of layer F2, the gain-frequency product is Gν. Assuming V B =0.1V, M s2 =200 G, w=1 nm, p=0.4, P 1 =1, P 2 =0.3, P 3 =1, and T=0.1, the gain-frequency product Gν=10 GHz.
Application of the transmission mode of spin transfer to data storage advantageously provides writing at high frequency, high storage density, and low power.
In applications of the reflection mode of spin transfer to active integrated computer and communications circuitry, high circuit density, high-frequency operation, low supply voltage, and low switch energy is achieved. In addition, the cooperative nature of ferromagnetism or ferrimagnetism provides non-volatility, radiation resistance, and a high degree of thermal stability in a small memory cell, which are desirable in military and space applications. When fabricating devices with lithography linewidth in the 10-100 nm range, there is the low expense implied by the need for only a single mask for the core of the device, instead of the minimum of 4 mutually registered masks needed for the core of a comparable semiconductor device. The lithography for the interconnections and the tolerance of their registration to the magnetic core can have larger and less costly dimensional scales, if desired.
Having thus described the preferred and other embodiments of the present invention, it will be understood that changes may be made in the size, shape and configuration of the parts described herein without departing from the present invention as recited in the claims. | In the present invention, electrons flow through a free or excitable magnet, or reflect from it, to make its magnetization respond. To accomplish this, the spin vectors of the flowing electrons are preferentially polarized by an auxiliary ferromagnet, whose moment orientation is fixed. The electrons flow between the fixed and free ferromagnets through a non-magnetic metallic spacer which is thick enough to make the static inter-magnetic exchange coupling negligible. While transmitting thru or reflecting from the free ferromagnet, the spins of the moving electrons interact by quantum-mechanical exchange with the local, permanently present, spontaneously-polarized electron spins of the free magnet. This interaction causes a transfer of vectorial angular momentum between the several metallic layers in the device which causes the magnetization vector of the free magnet to change its direction continually with time. Thus excited, the magnetization vector will precess about its original axis. The precession cone angle will either attain a new equilibrium value which will be sustained by the current or will increase beyond 90° and precess with decreasing amplitude until the magnetization vector has reversed by 180° from its initial direction (i.e., switched). | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
APPENDIX
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention is in the field of ergonomic supports for seats, especially automobile seats.
[0006] 2. Prior Art
[0007] Ergonomic supports for seats, especially automobile seats that impart a massage type effect on the seat occupant, are known in the art. See, e.g., U.S. patent application Ser. No. 09/536,425, incorporated by reference herein. Typically such prior art massage systems involve an active portion which moves toward and away from a portion of the seat occupant's anatomy to be supported, for example the lumbar spine. The active portion includes a surface that can be put into a variety of selectable positions supporting the spine to a greater or lesser degree. The moving or active portion of the lumbar support is typically a bowing or arching surface movable from a substantially flat position to a substantially bowed position which provides lumbar support.
[0008] The prior art devices also require a static portion. For example guide rails—which do not move—provide an anchor along which the active portion can slide or otherwise move through its range of selectable positions.
[0009] Alternative designs include push paddle type supports that extend or retract at the end of a linkage or through a channel. See, e.g., U.S. patent application Ser. No. 09/798,657, incorporated by reference herein. Still other options include strap devices that can be tightened or loosened in their relationship with a fixed component in order to move a supporting surface closer or further away from the spine of the seat occupant. See, e.g., U.S. Pat. No. 5,769,490, incorporated by reference herein. Generically, all of these systems have a moving or active portion and a static portion having some type of anchor on which the active portion is mounted and against which it can move to support the load of the seat occupant's weight.
[0010] Ergonomic supports for seats have actuating linkages. Frequently these linkages are traction cables such as Bowden cables. Bowden cables are comprised of a conduit containing a wire that slides axially through the conduit (also “sleeve”, or “sheath”) to apply or release traction on the active portion of the lumbar support. The traction moves the active portion into its supporting position and the release of the traction moves the active portion out of its supporting position. For example, in the arching type of ergonomic support the Bowden cable sleeve is mounted to one end of the arching pressure surface of the active portion and the Bowden cable wire is mounted to another end of the active pressure surface. Thereby, traction on the wire draws the two ends of the arching surface towards one another, inducing the arch that supports the seat occupant. Release of the tension allows the arching pressure surface to return to its flat position. Alternative actuating linkages may include rods, wires, rack and pinion devices, compression arrangements, eccentric wheels and the like. See, e.g., U.S. Pat. No. 5,498,063, incorporated by reference herein.
[0011] Some prior art lumbar supports cycled automatically through a range of motion. See, e.g., U.S. Pat. No. 6,007,151, incorporated by reference herein.
[0012] In the class of lumbar supports known in the art as massage systems, the pressure surface or active portion is modified by having rollers. The rollers are intended to impart a massage type feel to the seat occupant. Accordingly, the active portions are required to support an array of axles or pins on which to mount rollers, along with supporting the array of rollers themselves. The roller arrays in the prior art can be heavy, expensive and cumbersome. Moreover, the additional comfort imparted to the seat occupant by the presence of rollers is often only marginally better than the comfort afforded by the movement of the active portion of the lumbar support in the first place. In some configurations in some seats, empirical evidence indicates that rolling can be eliminated without sacrificing passenger comfort.
[0013] The presence of heavy and cumbersome active portions having roller arrays has, in the prior art, required rigid mounting of actuators. Actuators can be manual, but more typically are electrical motors for massaging systems. The actuators generally have an electrical motor operatively engaged with a gear assembly in a housing. The gear assembly typically has a seat or mount for one linkage portion, for example the wire of the Bowden cable, and the housing will have a seat or a mount for another portion of the linkage, for example the Bowden cable conduit. Because a heavy gauge of active portion components is necessary to support an array of rollers, larger motors and actuators are required to move the active portion on prior art massage systems. Moreover, the actuators and motors must be rigidly mounted to the static portion or anchor portion of the ergonomic support. Rigid mounting requires brackets which add further weight and expense.
[0014] Seat assemblers consider the “package size” of the entire device to be the widest, tallest and thickest dimensions of the ergonomic support unit as a whole. There is a continuing need in the furniture and automobile seat industry for reducing the total package size and weight, as well as the expense of ergonomic supports. Proliferating comfort systems in seats, such as heating and cooling ducts, require that traditional ergonomic devices such as lumbar supports should be made smaller and lighter. The prior art massage systems were large, heavy and expensive for two primary reasons. Large heavy active portions were required to support an array of rollers, and heavy mounting brackets were used to hold motors and actuators to the static portion of the unit. There is a need in the industry to reduce the weight, size and expense of the roller array on the active portion of a massaging lumbar support, and to reduce the width, thickness and weight of the unit as a whole, particularly by disengaging the actuators from being mounted directly to the static portion of the lumbar support.
SUMMARY OF THE INVENTION
[0015] The present invention is a massaging ergonomic support, such as lumbar support, that is smaller, thinner, lighter and more economical than prior art massaging lumbar supports. The present invention imparts the tactile effect of massaging, but without rollers. It does so by using an active portion or pressure surface that has integral undulations, corrugations or bumps on it, rather than being smooth. These surface variations may be imparted to the pressure surface of the active portion through molding in plastic or stamping in metal.
[0016] The massage lumbar support of the present invention further reduces size, weight and expense by eliminating the need for actuators to be directly mounted to the static portion of the ergonomic support. In the present invention, actuator gearboxes and motors are connected to the static and/or active portions of the lumbar support only by the actuating linkage, such as a Bowden cable. The weight and size of the mounting brackets is thereby saved. Instead, the actuators are capable of being mounted directly on any seat-frame. Accordingly, the added advantage of being readily customizable for mounting in any seat-frame is gained. Moreover, the size and power of the actuators and motors required to move the present pressure surface with molded surface variations is not as great as that required for prior art massaging lumbar supports.
[0017] Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and together with the description, serve to explain the principles of the invention. In the drawings:
[0019] FIG. 1 ; is a front view of prior art massaging lumbar support;
[0020] FIG. 2 ; is a front, perspective view of the arching pressure surface of the prior art device, with a roller array;
[0021] FIG. 3 ; is a front view of the present massage system;
[0022] FIG. 4 ; is a perspective view of the massage system;
[0023] FIG. 5 ; is a side view of the massage system; and
[0024] FIG. 6 ; is a cross section of the pressure surface of the present massage system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to the accompanying drawings in which like reference numbers indicate like elements, FIG. 1 illustrates a prior art massaging lumbar support. The prior art support has a static portion 10 . In the depicted embodiment this is a pair of guide rails. An active portion 12 is an arching pressure surface. The arching pressure surface of the prior art supports an array of rollers 14 . Actuators 16 move the active portion 12 up and down and in and out. One or both of the prior art actuators 16 were held onto the static portion 10 by brackets 18 .
[0026] FIG. 2 is a perspective view of an arching pressure surface for a prior art massaging lumbar support. As can be seen, the arching pressure surface 12 supported an array of rollers 14 . Each of the rollers 14 had to be supported by an axle or pin 20 . The axles and pins had to be fixated to the arching pressure surface 12 by rivets, welds or the like 22 . This structure is heavy, complex, expensive and cumbersome. This size, weight and expense makes the prior art devices unfeasible for automobile seats outside the class of large, luxury automobiles.
[0027] Referring now to FIGS. 3, 4 and 5 which are front, perspective and side views, respectively, of the massage system apparatus of the present invention, the massage system is capable of being mounted on preexisting static portions 52 without requiring any expensive modification to the static portions. The same principle would be true of preexisting static portions for push paddle or tensioning strap type lumbar supports. The static portion 52 —which are guide rails in the depicted embodiment—will mount to any seat frame (not shown) according to mounting techniques known in the prior art.
[0028] The active portion 54 has a textured, non-smooth surface with waves, corrugations undulations or bumps for imparting the desired tactile effect to a seat occupant. The active portion 54 has a pressure surface with a base level, that is “smooth.” That is, the base level of the pressure surface is like the pressure surface in non-massaging examples of the prior art; when in a base position it is substantially flat and when it is in an arched position it is curvilinear along a continuous, un-varied or “smooth” path. The waves, corregations or other embodiments of the present invention rise or sink from the base level and vary its profile. The variations from the base level of a smooth profile may collectively be referred to as “convexities.” It is these convexities that impart a massaging effect on a seat occupant as the pressure surface of the active portion of the lumbar support moves in and out or up and down.
[0029] Push paddle supports will have a pressure surface base level that does not change profile, but is extended or retracted for support. Tensioning straps have a pressure surface that does change profile in use, some times from concave to flat or from flat to convex. In either case a massage effect may be achieved, in advance over the prior art, by adding the convexities of the present invention to the base levels of those pressure surfaces.
[0030] Other aspects of the active portion 54 , i.e., its interaction with the static portion 52 and actuators 56 A and 56 B, also remain according to the prior art. That is, in the depicted arching pressure surface embodiment of the present invention, the arching pressure surface 54 will have sliding mounts engaging the static guide rails 52 . Moreover, Bowden cable attachments to the arching pressure surface 54 will apply and release traction according to the methods known in the prior art through Bowden cables 60 . Likewise, in other embodiments not depicted, the interaction of an active portion, for example a push paddle or tensioning strap, with a static portion, for example a push paddle linkage or a strap anchor and tightener, are unchanged, and remain as dictated by the prior art. The present invention may be applied to augment pneumatic systems as well. See, e.g., U.S. Pat. No. 5,637,076, incorporated by reference herein.
[0031] The pressure surface facing and acting upon a seat occupant has novel surface characteristics according to the apparatus and method of the present invention. The arching pressure surface 54 is non-smooth on its face interacting with the upholstery or cushion that overlies it and through which the pressure surface imparts a tactile effect on the seat occupant. It is within the scope of the present invention that the arching pressure surface have any conceivable surface characteristic, including without limitation, waves, undulations, bumps, corrugations, semi-cylindrical projections, convexities and the like. In the depicted embodiment, simple semi-hemispherical “bumps” are on the arching pressure surface. Such surface characteristics will move in relation to a seat occupant when the active portion of the ergonomic support is activated, in a manner that will have the same effect as the prior art rollers on massage systems. That is, there will be some necessary movement of the “bumps” orthogonal to the in and out motion of the arching pressure surface, concomitant with adjustment of. the arching pressure surface. Also, more directly, the bumps will move in a substantially vertical direction with the arching pressure surface, as the actuators 56 A or 56 B move the entire arching pressure surface 54 up and down on the static portion 52 . The movement of the surface convexities will impart a massaging-type comfort to the seat occupant. This will be true both as the pressure surface remains static and, more especially, as it is moved up and down and in and out.
[0032] The stimulating effect on the seat occupant can be maintained, in some embodiments, by the addition of the cycling technology known in the prior art, (as in previously referenced U.S. Pat. No. 6,007,151) which allows the pressure surface to move in and out automatically in cycles according to user controlled settings.
[0033] The amplitude and frequency of the surface undulations in the arching pressure surface 54 may be any of a wide variety of values. The preferred range is from 3 to 15 millimeters in both amplitude (depth) and frequency (separation). Varying the depth and separation of bumps or undulations allows the system of the present invention to be customizable to various seats, whether furniture or automobile seats, various customer parameters for the thickness of cushioning and/or upholstery to be placed over the arching pressure surface, or the amount of massage effect requested by a customer. The shape of the surface variations may also be any of a broad range of shapes and still be within the scope of the present invention. A broad range further increases customer choices for the tactile effect to be selected and for compatability with the other components of the seat into which the ergonomic support is to be installed. Accordingly, non-smooth surface variations may include hemispherical shapes, semi-cylindrical shapes, any parallelogram, sinusoidal patterns, undulations, corrugations or waves of varying, truncated, uniform or changing amplitude and frequency or virtually any other non-smooth pattern or configuration.
[0034] Stamping or molding such surface variations into the pressure surface greatly reduces the weight, size and expense of massage unit while achieving comfort levels, lumbar fatigue relief, and tactile effects substantially equivalent, or nearly so, with the prior art roller massage units. This is true whether the active portion of the lumbar support is an arching pressure surface as depicted herein, or alternatively is a push paddle or tensioning strap type support. The weight, cost, assembly time and expense of riveting roller pins or axles to an active pressure surface, installing the rollers on the axles and capping the ends of the axles to prevent the rollers from coming off of them, are all saved. A single stamped metal or molded plastic unit is substantially lighter than the fabricated assembly of the prior art roller arrays. While the stamped or molded variable pressure surface of the present invention has depth, its operative engagement to the static portion and to the actuating linkage are simpler and more streamlined, thereby saving space in terms of the overall depth of the entire unit, or “package”.
[0035] FIG. 6 is a schematic cross-section of one potential embodiment of the variable pressure surface of the present invention. There semi-circles 62 indicate a cross-section of hemispherical bumps stamped or molded into the otherwise flat base surface 64 of the pressure surface.
[0036] The other aspect of the present system that saves weight, space and expense is the elimination of mounting brackets for the actuators. By eliminating the need for a heavy pressure surface required for the support of a roller array, the present invention makes it possible to use smaller, less powerful and less expensive electric motors to actuate smaller and less expensive actuators and gear boxes. Moreover, the reduced power needs eliminate the requirement for added rigidity that cause prior art massage units to mount the actuators to the static portions of their supports with heavy brackets ( 18 on FIG. 1 ). It will be appreciated by those of skill in the art that even if the novel pressure surface of the present invention did not change the power and rigidity requirements for the actuators, the elimination of the brackets would still achieve package size reduction and installation flexibility of the ergonomic support unit of the present system.
[0037] In the depicted embodiment, actuators 56 A and 56 B are operatively engaged with the static portion 52 and active portion 54 of the ergonomic support through Bowden cables 58 and 60 . These traction cables move a tractive wire through a sleeve or conduit, which is actuated by the actuator gear box powered in turn by the electric motor. Drawing the wire into the sleeve puts tractive force on the ergonomic support unit in order to move the active portion 54 relative to the static portion 52 . In most configurations, traction on the Bowden cable causes the active portion to arch, tighten or extend a pressure surface out towards the seat occupant or support, and relaxation of the wire within the sleeve reduces tension in order to return an active portion to a flatter base position.
[0038] Another common motion of ergonomic support units performed by actuation linkages such as Bowden cables 58 and 60 is to raise or lower the entire active portion of the support unit. In the depicted embodiment, a Bowden cable raises the arching pressure surface 54 upwards or downwards on the static guide rails 52 .
[0039] The advantages gained by releasing the actuator mounting from the static portion 52 of the support unit include a greater adaptability for mounting of the unit in varying seat frames; a great reduction in the “packaging” size, and savings in weight and cost by removing the added part of a mounting bracket. Since the seat frame, on the periphery of the seat, and devices mounted to it are generally not considered to be within the “packaging,” ergonomic support units with independent actuators linked by adaptable actuation linkages such as Bowden cables 58 and 60 , allow the ergonomic support system of the present invention to be marketed as a much smaller “package.”
[0040] In view of the foregoing, it will be seen that the several advantages of the invention are achieved and attained.
[0041] The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
[0042] As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. For example, push paddle supports or tensioning strap type supports could employ the present invention. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. | An ergonomic support mountable on various seat frames has a static portion ( 52 ) with anchors and mounts. The mounts adapt to fix said static portion to varying seat frames. An active portion ( 54 ) is operatively engaged with the anchors of the static portion such that the active portion can move in and out of a plane defined by the frame of the seat. The active portion has a pressure surface with a smooth base level ( 64 ). There are convexities ( 62 ) in the base level that impart a massage effect on a seat occupant. At least one actuator engages the active portion but only by an actuating linkage. | 1 |
FIELD OF THE INVENTION
The present invention relates to light monitors, and in particular, to a light monitor on a single chip.
BACKGROUND OF THE INVENTION
Recent years have seen rapid growth in the demand for inexpensive, lightweight and robust measuring and control devices. This demand has been manifested in the rapid developments in the field of miniaturized devices, such as lab-on-a-chip.
Display backlighting significantly contributes to the battery consumption of mobile devices, such as notebook computers, PDAs and mobile phones. Consequently, it is possible to considerably increase the useful lifetime of a battery by controlling the backlights so that they are dimmed in dark conditions and are only increased when there are high ambient light levels.
Beyond the above specific example, the provision of inexpensive, miniaturized light monitoring sensors and control systems (e.g., for car headlights, large building lighting networks, street lighting networks, etc.) will clearly provide significant economic and environmental benefits. Traditional light sensors typically produce an analog output signal. One of the main challenges encountered in previous attempts to provide integrated miniaturized light sensing and control systems has been the problem of combining analog signal processing circuitry with digital signal processing circuitry on the same chip.
Accordingly, prior art on-chip light sensors have typically possessed limited data processing capabilities. This has created particular problems since it means that such devices have limited, if any, ability to compensate for manufacturing variations between components.
For instance, the Microsemi LX1970 and 71 (http://www.microsemi.com/micnotes/1403. pdf) device is an 8-pin dumb-sensor that requires continual monitoring. Similarly, the TDK BCS series requires continual monitoring. The Texas Instruments TAOS (TSL230R/A/B, TSL235R, TSL245) devices possess a narrow dynamic range with no fine control on the limit and no matching or compensation for component errors.
Since the present invention relates to imaging sensors, and more particularly, to a light to frequency converter, it is useful at this point to briefly review the properties of CMOS image sensors and the operation of the light to frequency converter circuit.
A brief overview of CMOS image sensors will now be discussed. Recent advances in the design and fabrication of complementary metal oxide semiconductor (CMOS) chips have meant that CMOS imaging sensors are adopting a more dominant position in the low-cost imaging market.
One of the main advantages of CMOS imaging sensors is that they can be produced using standard fabrication procedures which are already widely used for producing CMOS chips for computer processors, memory chips, etc. Furthermore, the signal processing and control circuitry for a CMOS imaging sensor can be integrated directly onto the CMOS chip.
A light to frequency converter circuit will now be discussed. As an overview, a light to frequency (LTF) converter, as described in U.S. Pat. No. 5,850,195 discloses a CMOS imaging sensor with a large dynamic range. The LTF converter architecture possesses several advantages over traditional imaging sensors. These advantages primarily reside in the following features: integration capacitance tolerance, integration capacitance size, and frequency output. These features will be discussed in more detail below.
With respect to integration capacitance tolerance in a conventional light sensor, a photodiode's capacitance is defined by its well capacitance. However, this feature can be hard to control. Consequently, it is difficult to produce an array of photodiodes with matched sensitivity.
In contrast, an LTF converter employs a charge amplifier structure, which ensures that the effective capacitance of the LTF converter is determined by an integration capacitance provided by a feedback capacitor. Since capacitors can be manufactured with tighter controls over their capacitance (e.g., poly-poly or metal-metal capacitors), the variability in the capacitance of the individual LTF converters in an LTF converter array is less than that of a similar number of traditional light sensors.
With respect to integration capacitance size, increasing the size of a photodiode should in principle increase its ability to collect incident photons. As a result, this increases its sensitivity to incident light. Larger photodiodes also possess an increased parasitic capacitance. This has the effect of negating the ability of the photodiode to collect more photons, and thereby eliminates any sensitivity benefits of the increased photodiode size.
In contrast, the LTF converter employs a charge amplifier structure that isolates the capacitance of the LTF converter's photodiode from the rest of the LTF converter circuitry. This ensures that the effective capacitance of the LTF converter is determined by the capacitance of its feedback capacitor (as described above). Consequently, it is possible to use a large photodiode in an LTF converter while retaining a small overall circuit capacitance, and thereby producing a high sensitivity detector.
With respect to frequency output, on-chip signal processing with traditional analog light sensors is relatively sensitive to noise from the other on-chip circuitry. In contrast, the charge amplifier structure of an LTF converter is readily combined with a comparator to produce a digital signal whose frequency is proportional to the light on the LTF converter's photodiode.
The digital signal produced by an LTF converter is both robust and measurable over a large dynamic range (i.e., 140 dB of dynamic range is practical with the charge amplifier architecture). In addition, the LTF converter system is auto-exposing, insofar as no external control loop is required to ensure that an LTF converter's photodiode pixel does not saturate.
The operation of an LTF converter will now be described below with reference to FIGS. 1-5 . The LTF converter comprises a control circuit 4 , a photodiode 6 and a current to digital signal converter 8 . The current to digital signal converter 8 uses a switched-capacitor charge metering technique to convert a photo-current from the photodiode 6 to a digital signal of a specific frequency. The current to digital signal converter 8 comprises a bias circuit 10 (which controls the maximum operating speed of the digital signal converter 8 ), an amplifier circuit 14 , a switched feedback capacitor 16 in a charge sensing amplifier circuit (not shown), a comparator 18 and a monostable multivibrator circuit 19 .
Referring to FIG. 2 , the charge sensing amplifier circuit 20 effectively isolates the remaining circuitry of the current to digital signal converter (not shown) from the large capacitance of the photodiode 6 (<100 pF). The charge sensing amplifier 20 comprises an operational amplifier 22 configured in a closed loop configuration with its non-inverting input coupled to a reference voltage (V rt ) and its inverting input connected to the feedback capacitor 16 . The reference voltage (V rt ) is set as low as possible to increase voltage swing while maintaining the depletion region of the PN junction of the LTF converter. The reference voltage (V rt ) is usually set to approximately 0.7V.
Since the operational amplifier 22 has a large input impedance, virtually no current flows through it. Consequently, the output of the operational amplifier 22 changes to ensure that the inverting and non-inverting inputs of the operational amplifier 22 remain at the same potential (i.e., V rt ) In the process, a current flows through the feedback capacitor 16 which has the same magnitude (but opposite sign) to the photo-current generated by the photodiode 6 (I pd )
Equation (1) below shows the relationship between the output voltage (V out1 ) from the charge sensing amplifier 20 and the photo-current generated by the photodiode 6 .
V
out1
=
-
I
pd
T
int
C
fb
(
1
)
From the above expression it can be seen that the output voltage (V out1 ) from the charge sensing amplifier 20 is independent of the photodiode's 6 capacitance. Referring to FIG. 3 , the output voltage (V out1 ) from the charge sensing amplifier 20 is accumulated until it reaches a maximum value (V outmax ) at which point it is reset.
FIG. 4 shows a system for resetting an integrating amplifier (not shown) in the amplifier circuit 14 . In this system, the output voltage from the amplifier circuit 14 (V out2 ) is transmitted to the comparator 18 . In the comparator 18 , the output voltage (V out2 ) is compared against a reference voltage (V ref ). If the output voltage (V out2 ) exceeds the reference voltage (V ref ), the comparator 18 transmits a control signal (CTRL) to the monostable multivibrator circuit 19 . In response to the control signal (CTRL), the monostable multivibrator circuit 19 emits a pulsed signal (RESET) to discharge the feedback capacitor 16 .
Consequently, the frequency of the control signal (CTRL) is also proportional to the photodiode current I pd (assuming that the integrating amplifier in the amplifier circuit 14 settles completely during the period of the control signal (CTRL)). The control signal (CTRL) is also fed to a divide-by-two circuit 30 to form the overall output signal (F out ) from the LTF converter. By employing a divide by two circuit 30 , a symmetrical output signal is produced, which is more reliably detected since it no longer includes short pulses.
Returning to equation (1), since the rate of change (slope) of the output voltage (V out1 ) from the charge sensing amplifier is proportional to the intensity of the incident light, the frequency of the overall output signal (F out ) from the LTF converter is also proportional to the incident light intensity. This proportionality is more clearly expressed in equation (2) below.
F
out
=
I
pd
2
C
fb
(
V
ref
-
V
rt
)
(
2
)
It can be seen from equation (2) that although the overall output signal (F out ) from the LTF converter is proportional to the photocurrent (I pd ) from the photodiode, it is also dependent on the reference voltages (V ref , V rt ) and the capacitance of the feedback capacitor C fb . While it is possible to use bandgap reference voltages to accurately produce the above reference voltages, the capacitance of the feedback capacitor is less easily controlled since it is typically subjected to manufacturing variations.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, a light monitor comprises an LTF converter, thresholding means and light intensity calculating means. The LTF converter is in communication with the light intensity calculating means, and the light intensity calculating means is in communication with the thresholding means. The light monitor is provided on a single chip.
The light intensity calculating means may comprise a counter and clocking signal generating means to provide a clocking signal for the counter. The clocking signal generating means may comprise a constant current source in communication with a charge sensing amplifier circuit comprising a first feedback capacitor.
The light monitor may comprise means for scaling a signal generated by the LTF converter in accordance with the clocking signal, and means for accumulating a resulting scaled signal in the counter to calculate a scaled measurement variable.
The light intensity calculating means may comprise a counter, reference signal generating means and a crystal oscillator whose output provides a clocking signal for the counter. The counter may comprise means for accumulating a reference signal generated by the reference signal generating means to calculate a reference variable.
The counter may further comprise gain adjustment calculating means to calculate a gain adjustment that includes the deviation between the reference variable and an expected value of same.
The counter may further comprise means for accumulating a signal from the LTF converter to calculate a measurement variable. The counter may also further comprise means of adjusting the measurement variable in accordance with the gain adjustment to calculate a scaled measurement variable.
The thresholding means may comprise at least one register adapted to contain a value of a first limit variable. The thresholding means may further comprise means of comparing a value of the scaled measurement variable from the light intensity calculating means with a value of the first limit variable.
Preferably, the thresholding means may comprise transmission means for transmitting to an external system an indicator of whether the value of the scaled measurement variable exceeds the value of the first limit variable. The transmitting means may comprise a single output pin.
Optionally, the thresholding means may comprise at least two registers adapted to contain a value of a first limit variable and a second limit variable. The thresholding means may further comprise means of comparing a value of the scaled measurement variable with a value of the first limit variable and the second limit variable.
The thresholding means may comprise transmission means for transmitting to an external system an indicator of whether the value of the scaled measurement variable exceeds the value of the first limit variable; is less than the value of the second limit variable; or is between the values of the first limit variable and the second limit variable.
The transmitting means may be in communication with the external system through a bi-directional interface. The bi-directional interface may be an I2C interface, an SPI interface or a CAN interface. The bi-directional interface may be a wireless interface such as a Zigbee interface.
The thresholding means may transmit the values of the first and second limit variables to the registers through the bi-directional interface.
According to a second aspect of the invention, a lighting control system comprises a light source, a light monitor according to the first aspect, and a control device. The light monitor may comprise means of communicating a first signal representing the intensity of ambient light to the control means. The control means may comprise means of transmitting a control signal to the light source in response to the received count signal. The light source may comprise means of altering its output in accordance with the received control signal.
According to a third aspect of the invention, a portable computing device back-light control system comprises the lighting control system according to the second aspect.
According to a fourth aspect of the invention, a mobile telecommunications device back-light control system comprises the lighting control system according to the second aspect.
According to a fifth aspect of the invention, a street lighting control system comprises the lighting control system according to the second aspect.
According to the sixth aspect of the invention, an automotive lighting control system comprises the lighting control system according to the second aspect. The automotive lighting system may comprise headlamps, and a dashboard illumination system.
The present invention thus combines an LTF converter with signal processing circuitry to provide a light monitor on a chip. The data from such light monitors could then be used in a control strategy as outlined above.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a block diagram of an LTF converter according to the prior art;
FIG. 2 is a simplified circuit diagram of a charge sensing amplifier used in the LTF converter shown in FIG. 1 ;
FIG. 3 is a graph of the output voltage from the charge sensing amplifier shown in FIG. 2 , during a period of time in which the LTF converter shown in FIG. 1 is exposed to light;
FIG. 4 is a detailed block diagram of the current to digital signal converter in the LTF converter shown in FIG. 1 ;
FIG. 5 is a timing diagram for the following signals in the LTF converter shown in FIG. 1 : a reference voltage (V ref ), an output voltage (V out2 ), a pulsed reset signal, and an overall output signal (F out );
FIG. 6 is a block diagram of the light monitor of the present invention in use in a light control system;
FIG. 7 is a block diagram showing an overview of a first embodiment of the LTF converter light intensity calculator component of the light monitor shown in FIG. 6 ;
FIG. 8 is a block diagram of the clock component of the LTF converter light intensity calculator shown in FIG. 7 ;
FIG. 9 is a block diagram of the circuit components of the constant current source of the clock component shown in FIG. 8 ;
FIG. 10 is a block diagram showing an overview of a second embodiment of the LTF converter light intensity calculator component of the light monitor shown in FIG. 6 ;
FIG. 11 is a block diagram of a first embodiment of a light intensity comparator component of the light monitor shown in FIG. 6 , wherein the light intensity comparator is provided with a wired interface;
FIG. 12 is a block diagram of a second embodiment of a light intensity comparator component of the light monitor shown in FIG. 6 , wherein the light intensity comparator is provided with a single pin output and a memory threshold load; and
FIG. 13 is a block diagram of a third embodiment of a light intensity comparator component of the light monitor shown in FIG. 6 , wherein the light intensity comparator is provided with a wireless interface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the sake of clarity and consistency, the thresholding means and the light intensity calculating means will be respectively referred to in the following description as a thresholding comparator and an LTF converter light intensity calculator. Similarly, in the following description of the first embodiment of the invention, the clocking signal generating means will be known as a signal generator.
Most control strategies are based upon the comparison of the value of a measured variable with a target value for that variable. Referring to FIG. 6 , the light monitor 500 comprises an LTF converter 50 , a LTF converter light intensity calculator 60 and a threshold comparator 70 . The output signal from the light monitor may then be transmitted to a distributed control system or other suitable controller 80 . In response to the data from the light monitor 500 , the controller 80 adjusts the power to a light source 90 .
A light intensity calculator 50 will initially be discussed. As a broad overview and in reference to FIG. 7 , in a first embodiment of the LTF converter light intensity calculator 150 , the digital output signal from an LTF converter 100 is fed into a counter 26 together with a reference signal of a fixed pre-defined frequency (F sysclk ). The reference signal is provided by a signal generator 28 and is used to provide a clocking mechanism for the counter 26 . The counter increments a COUNT variable in accordance with the reference signal (F sysclk ) within the period of the pulse received from the LTF converter 100 . Consequently, the value of the COUNT variable accumulated within the period of the pulse from the LTF converter 100 provides a quantized measurement of the intensity of the light detected by the LTF converter's photodiode.
The relationship between the COUNT variable and the frequency of the output signal from the LTF converter 100 is shown in equation (3) below.
COUNT
=
F
sysclk
F
out
=
F
sysclk
(
I
pd
[
2
×
(
V
ref
-
V
rt
)
]
×
C
fb
)
(
3
)
In this equation, F out and F sysclk respectively represent the frequency of the output signal from the LTF converter 100 and the signal generator 28 .
A system clock circuit will now be discussed with reference to FIG. 8 . The reference signal (F syscik ) from the signal generator 28 is produced using the same charge sensing amplifier circuit 120 (comprising a comparator 122 , a feedback capacitor 124 and a switch 125 ), amplifier 114 , comparator 118 , monostable multivibrator circuit 119 and capacitor resetting system 130 as that previously described for the LTF converter.
However, in the case of the signal generator 28 , the input current to the charge sensing amplifier circuit 120 is provided by a constant current source 30 (instead of the photodiode used in an LTF converter). The constant current source 30 is produced using a bandgap reference voltage 32 and voltage controlled current source 34 as shown in FIG. 9 .
A count measurement and capacitance variability compensation will now be discussed. Returning to FIGS. 7 and 8 , the current from the constant current source 30 thus fixes the frequency of the output signal (F sysclk ) from the signal generator 28 as shown in equation (4) below.
F
sysclk
=
I
ref
[
2
×
(
V
ref
-
V
rt
)
×
C
fb2
]
(
4
)
Combining equations (3) and (4) results in the following equation for the COUNT variable from the counter 26 .
COUNT
=
C
fb
C
fb2
×
I
pd
I
ref
(
5
)
From the above equation it can be seen that the COUNT variable is effectively a function of the ratio of the capacitances of the feedback capacitors in the LTF converter 100 and the signal generator 28 .
The feedback capacitors in the LTF converter 100 and the signal generator 28 are typically constructed in the metal layers of the chip embodying the two circuits. Accordingly, the capacitance of either of the two feedback capacitors (C fb or C fb2 ) can be generically described by the following equation:
C = ∈ ox A t ox ( 6 )
where A represents the area of the capacitor and ε ox and t ox respectively represent the dielectric constant and thickness of the silicon dioxide in the chip.
Processes such as chemical metal polishing (CMP) can cause variations to occur in the oxide thickness of capacitors, and thereby cause variations in their capacitances. To ensure that the conversion of charge to voltage in both the LTF converter and the clock are equivalent, the feedback capacitors of both systems (C fb and C fb2 ) are matched.
Consequently, referring to equation (5) any part-to-part variations that occur between the two feedback capacitors will be cancelled out in the calculation of the ratio of the two capacitances in the Count measurement.
A second embodiment of the LTF converter light intensity calculator will now be discussed with reference to FIG. 10 . A low power second embodiment of the LTF converter light intensity calculator comprises an LTF converter 250 , a reference signal generator 228 of the same structure as the reference signal generator employed in the first embodiment of the LTF converter light intensity calculator. However, in contrast with the first embodiment of the LTF converter light intensity calculator, in the second embodiment the reference signal is not used to clock the counter 126 . Instead, the counter 126 is clocked by an external crystal oscillator 29 .
In the second embodiment of the LTF converter light intensity calculator, the reference signal is periodically transmitted to the counter for calibration purposes. More particularly, since the frequency of the reference signal F sysclk is known, it is possible to predict the value of the COUNT variable that would be accumulated over a fixed time interval, when the reference signal is input to the counter. Any deviation from the expected value of the COUNT variable (COUNT ref ) can be ascribed to processing or other drift/variations in the LTF converter light intensity calculator. This deviation can be treated as a calibrating scaling factor and used to correct the COUNT variable measured from the LTF converter.
Since, the reference signal is not continually required to clock the counter in the second embodiment of the LTF converter light intensity calculator, the reference signal generator does not represent as significant a drain on the power of the light monitor.
A light intensity threshold comparator 70 will now be discussed with reference to FIG. 11 . The first embodiment of the light intensity threshold comparator 170 comprises a logic unit 36 in which the COUNT variable from the light intensity calculator 60 is compared against pre-defined upper and/or lower limits (α MAX and α MIN ). The light intensity threshold comparator 170 is provided with three logical output lines L 0 , L 1 and L 2 corresponding to three following logical states:
L 0 : COUNT<α MIN
L 1 :α MIN <COUNT<α MAX
L 2 : COUNT>α MAX
Accordingly, the value of the digital signal transmitted on each of these lines provides an indication of the logical status of the COUNT variable compared with the pre-defined upper and lower limits on same. These logical signals can then be transmitted to a simple controller (e.g., bang-bang controller).
The upper and lower limits α MAX and α MIN can be set through an interface 38 such as I2C, SPI or CAN. The absolute value of the Count measurement can also be transmitted through the interface 38 to a controller for the implementation of more sophisticated control algorithms.
FIG. 12 shows a second embodiment of the light intensity threshold comparator 270 in which the three logical output lines from the light intensity threshold comparator 270 are transmitted from a single pin output. This is achieved using a multiplexor 40 that is controlled via the interface 138 . In addition, the values of the upper and lower thresholds α MAX and α MIN can be automatically loaded from a memory (not shown) into the intensity threshold comparator 270 registers (not shown) via the interface 138 .
FIG. 13 shows a third embodiment of the light intensity threshold comparator 370 , in which the signals from the logical output lines L 0 , L 1 and L 2 (and the analog COUNT variable) are transmitted to a remote controller (not shown) through a wireless interface 238 rather than a specific output pin (as in the first and second embodiments of the light intensity threshold comparator). This could be achieved by a low power, low latency and inexpensive transmitter, such as a Zigbee transmitter. The light monitor can be readily included in an integrated circuit and is applicable to a broad range of devices including lighting control systems. An example lighting control system 125 is shown in FIG. 6 . More particularly, the lighting control system 125 is applicable to portable computing device backlighting control systems, mobile telecommunications device back-lighting control systems, street lighting control systems and automotive lighting control systems (i.e., headlight controllers and dashboard illumination controllers). It will be appreciated that those skilled in the art may employ standard techniques to implement the invention in these and other ways. Alterations and modifications may be made to the above without departing from the scope of the invention. | A light monitor includes a single semiconductor substrate. A light to frequency (LTF) converter is on the single semiconductor substrate, a threshold comparator is on the single semiconductor substrate and coupled to an output of the light to frequency converter, and a light intensity calculator is on the single semiconductor substrate and coupled to an output of the threshold comparator. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a distance measuring apparatus and to a method for measuring a distance from the apparatus to an object by emitting light which passes through a slit, taking an image obtained by light reflected by the object, and referring to a positional relationship between the light emitting position and the image taking position.
2. Description of the Related Art
Recently, CCD cameras and computer image processing techniques have been improved, and accordingly, three-dimensional measurement methods using images have become common. An example of such three-dimensional measurement methods using a CCD camera and the computer image processing is a light-section method. In the light-section method, a light beam passing through a slit or having a beam form obtained by passing through a slit is projected onto a target object to be measured, so as to virtually cut the object using a band-shaped light and a cut surface is observed in a direction other than the direction of the projected light beam. Here, owing to the laser technique, very fine and intense light beams can be obtained. Therefore, even an object having an irregular surface can be measured at high speed and with high accuracy by employing the three-dimensional measurement method using the light-section method.
More specifically, in the light-section method, a light beam which passes through a slit and is emitted from a unit (i.e., distance measuring apparatus) which has a CCD camera is reflected by a surface of a target object, and an image obtained by the reflected light is taken by the CCD camera. The distance between the target object and the unit is measured based on the direction of the emitted beam and the positions of the relevant light source and the CCD camera. Therefore, in order to measure the entire portion of the target object, the light beam which passes through the slit is gradually shifted on the surface of the target object, and an image obtained by the reflected light is taken every time the light beam is shifted.
This method of taking images while shifting the light beam which passed through a slit requires a long measurement time for measuring the entire portion of an object. In order to solve this problem, a plurality of light beams which pass through slits may be emitted from the distance measuring apparatus. In this case, the shift of the light beam on the target surface is unnecessary, and the entire image of the target object can be measured through a single image-taking process. In this method, some of the light beams passing through slits may be ineffective for taking an image. Therefore, in order to specify the ineffective light beams, a specific beam width, pattern, or color is assigned to each light beam, so as to identify the light beam which was used for taking each image.
However, when a floor surface or an obstacle on a floor surface is detected using the light-section method as an optical sensor of a self-controlled robot, the distance towards the target object and the shape of the target object are unknown. Therefore, if a specific width, pattern, or color is assigned to each light beam and images are taken using reflected light beams, a large burden is imposed on the image processing. Additionally, in order to specify each of a plurality of light beams which pass through slits and have different color, a color image taken by a color camera must be processed; thus, the equipment cost is high and a bigger burden is imposed on the complicated color-image processing, and as a result, the processing time is increased. Furthermore, a device for emitting light beams which pass through slits must have a complicated mechanism for assigning a specific width, pattern, or color to each beam.
SUMMARY OF THE INVENTION
In consideration of the above circumstances, an object of the present invention is to provide a distance measuring apparatus and method for measuring the entire image of a target object by employing a light-section method with a short measurement time, without assigning any specific feature to light beams having a beam form obtained by passing through slits.
Therefore, the present invention provides a distance measuring apparatus for measuring a distance to a target object by using a light-section method, comprising:
a beam emitting device for simultaneously emitting a plurality of light beams towards the target object, each beam having a beam form obtained by passing through a slit;
a first image taking device for taking an image obtained by light reflected by the target object, where the distance between the first image taking device and the beam emitting device is relatively short so as to obtain a wide distance area;
a second image taking device for taking an image obtained by light reflected by the target object, where the distance between the first image taking device and the beam emitting device is relatively long so as to obtain a high measurement accuracy of the distance;
a distance estimating section for estimating the distance to the target object based on the image taken by the first image taking device; and
a distance determining section for determining the distance to the target object based on the estimated result output from the distance estimating section and on the image taken by the second image taking device.
Preferably, the beam emitting device is positioned between the first image taking device and the second image taking device.
Typically, the beam emitting device includes a diffraction grating for obtaining said plurality of light beams.
Also typically, said plurality of light beams are laser beams.
The beam emitting device may include a beam diffusing element for diffusing a beam in a single plane so as to have said beam form.
Typically, the beam diffusing element has a cylindrical lens.
Typically, each of the first image taking device and the second image taking device comprises an interlaced scanning CCD camera.
The present invention also provides a self-controlled robot having a distance measuring apparatus as explained above.
Typically, the self-controlled robot is a bipedal robot having two legs.
In the self-controlled robot, it is possible that:
the distance estimating section has a section for estimating the height of the target object based on the image taken by the first image taking device; and
the self-controlled robot comprises an action plan determining section for determining an action plan of the robot based on the estimated result output from the distance estimating section; and
the distance determining section has a section for determining a landing position of a leg of the robot based on the action plan, the estimated result output from the distance estimating section, and the image taken by the second image taking section.
The present invention also provides a distance measuring method of measuring a distance to a target object by using a light-section method, comprising:
a beam emitting step of simultaneously emitting a plurality of light beams towards the target object, each beam having a beam form obtained by passing through a slit;
a first image taking step of taking an image obtained by light reflected by the target object, where the distance between the point where the image is taken and the position where the beams are emitted is relatively short so as to obtain a wide distance area;
a second image taking step of taking an image obtained by light reflected by the target object, where the distance between the point where the image is taken and the position where the beams are emitted is relatively long so as to obtain a high measurement accuracy of the distance;
a distance estimating step of estimating the distance to the target object based on the image taken in the first image taking step; and
a distance determining step of determining the distance to the target object based on the estimated result obtained in the distance estimating step and on the image taken in the second image taking step.
Typically, in the method, the position where the beams are emitted is positioned between the point where the image is taken in the first image taking step and the point where the image is taken in the second image taking step.
Preferably, the beam emitting step includes a beam diffusing step of diffusing a beam in a single plane so as to have said beam form.
According to the present invention, a plurality of light beams, each beam having a beam form obtained by passing through a slit, are simultaneously emitted, rough estimation of the distance is performed based on the image taken by the first image taking device, and the distance is determined using the image taken by the second image taking device with reference to the estimated results. Therefore, in a target area, highly accurate measurement of the distance is possible within a short measurement time. In addition, the above plurality of light beams can be generated using a single light source (i.e., beam emitting device); therefore, no color image is necessary, and image data taken by non-color cameras whose brightness data are known or obtained are processed. In addition, the above plurality of light beams can be generated using the diffraction grating and the beam diffusing element such as a cylindrical lens; thus, the structure of the beam emitting device (typically, laser light source) can be simplified.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the structure of an embodiment according to the present invention.
FIG. 2 is a block diagram showing the structure of the laser light source 11 in FIG. 1 .
FIG. 3 is a diagram showing the appearance of the bipedal robot 1 .
FIG. 4 is a diagram showing a state in which the laser beam is emitted from the optical system 2 .
FIG. 5 is a diagram showing a positional relationship between the laser light source 11 , the short, baseline length camera 12 , and the long baseline length camera 13 .
FIG. 6 is a flowchart showing the operation of the distance measurement.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the distance measuring apparatus as an embodiment according to the present invention will be explained in detail with reference to the drawings.
First, with reference to FIG. 3, a bipedal (i.e., two-legged) robot to which the distance measuring apparatus is attached will be explained. In FIG. 3, reference numeral 1 indicates a self-controlled bipedal robot (abbreviated to “robot”, hereinbelow), and reference numeral 2 indicates an optical unit of the distance measuring apparatus, which is attached at the height of the waist portion of the robot 1 . Reference numeral 3 indicates a laser emitting range of the optical unit 2 of the distance measuring apparatus. Here, the laser beam having a beam form obtained by passing through a slit (called a “slit” light beam, hereinbelow) is spread over 60 degrees in a single plane and the spread beam is emitted towards a floor surface 4 . In addition, the set of the optical unit 2 is arranged so that the “slit” laser beam is emitted onto a forward area from a tip of a foot of the robot 1 .
FIG. 1 is a block diagram showing the structure of the distance measuring apparatus of the present embodiment. In the figure, reference numeral 11 indicates a laser light source for;emitting a laser beam towards a target object, reference numeral 12 indicates a short baseline length camera arranged close to the laser light source 11 , that is, the distance between the laser light source and the camera 12 is short. The short baseline length camera 12 comprises an interlaced scanning CCD camera and has a short baseline length. Therefore, this short baseline length camera has a low accuracy for measuring distance; however, a large distance range in front of the robot 1 can be observed by the camera 12 . Reference numeral 13 indicates a long baseline length camera arranged away from the laser light source 11 , that is, the distance between the laser light source and the camera is long. The long baseline length camera 13 also comprises an interlaced scanning CCD camera but has a long baseline length. Therefore, this long baseline length camera 13 has a high accuracy for measuring distance; however, the distance range in front of the robot 1 is limited for this camera 13 . In addition, the short baseline length camera 12 and the long baseline length camera 13 can be operated using a synchronizing signal input from an external device.
Reference numeral 2 indicates the optical unit shown in the above-explained FIG. 3, and the optical unit 2 includes the laser light source 11 , the short baseline length camera 12 , and the long baseline length camera 13 . Reference numeral 14 indicates an emission control section for outputting an emission control signal used for controlling the emission of the laser beam, and outputting a vertical synchronizing signal to the short baseline length camera 12 and the long baseline length camera 13 . Reference numeral 15 indicates an image storing section having two image memories 15 a and 15 b for storing image signals (i.e., image data) output from the above two cameras. That is, the image storing section 15 respectively stores data of images taken by the short baseline length camera 12 and the long baseline length camera 13 in the image memories 15 a and 15 b.
Reference numeral 16 indicates a height estimating section for estimating the height of the target object based on the image data obtained by the short baseline length camera 12 and stored in the image memory 15 a.
Reference numeral 17 indicates an action planning section for determining an action plan of the robot 1 , based on the estimated results (output from the height estimating section) related to the target object. Here, the “action plan” means to determine, in advance, the action of the robot 1 in determination of its path of movement, based on the height of the target object estimated by the height estimating section 16 , more specifically, to determine whether the obstacle will be avoided when the robot advances, whether the robot will step over the obstacle, or the like.
Reference numeral 18 indicates a landing position determining section for determining how to raise a leg of the robot and where the foot of the raised leg will land, based on the action plan determined by the action planning section 17 and the height of the target object estimated by the height estimating section 16 .
Reference numeral 19 indicates a leg control section for controlling a section for driving the legs of the robot so as to land the foot of the relevant leg on the landing position determined by the landing position determining section 18 .
Next, with reference to FIG. 2, the detailed structure of the laser light source 11 in FIG. 1 will be explained.
FIG. 2 is a block diagram showing the structure of the laser light source 11 . In the figure, reference numeral 21 indicates a laser beam emitting section. Reference numeral 22 indicates a condenser lens for condensing the laser beam emitted from the laser beam emitting section 21 , so as to obtain a condensed beam. Reference numeral 23 indicates a diffraction grating for dividing the laser beam condensed through the condenser lens 22 into a plurality of beams. Here, the divided beams are aligned in the direction perpendicular to the plane of FIG. 2 . Reference numeral 24 indicates a beam diffusing lens using a cylindrical lens or the like. This beam diffusing lens is provided for diffusing each laser beam in a single plane so as to generate a beam having a beam form obtained by passing through a slit. That is, each beam is diffused by the beam diffusing lens 24 at a diffusion angle of 60 degrees, as shown in FIG. 2 .
In addition, in FIG. 2, reference numeral 4 indicates a floor surface, and reference symbol A indicates a point (on the floor) where a tip of a (front) foot of the robot 1 is present.
The optical system 2 is attached to the height of the waist of robot 1 , and FIG. 4 shows a state in which the laser beam is emitted under the above mounting condition. In FIG. 4, reference numeral 11 indicates the laser light source. Reference numeral 3 indicates a laser emitting range obtained by the laser emitted by the laser light source 11 onto the floor surface 4 . Here, the emitted laser beam is divided into five beams by the diffraction grating 23 , and each beam is diffused by 60 degrees through the beam diffusing lens 24 . These laser beams are emitted towards the floor surface 4 , and images obtained by the beams reflected by the floor surface are taken by the short baseline length camera 12 and the long baseline length camera 13 . Here, in the example of FIG. 4, the emitted laser beam is divided into five beams for convenience of explanations. However, in a practical example, angle B in FIG. 4 is 32 degrees and angle C is 1.6 degrees. Accordingly, the number of divided beams is 21 in this case.
Next, with reference to FIGS. 5 and 6, the operation of the measurement will be explained.
FIG. 5 is a diagram showing a positional relationship between the laser light source 11 , the short baseline length camera 12 , and the long baseline length camera 13 . Reference numeral 31 indicates a laser emitting range. Here, in order to make the figure easy to understand, only five beams are shown. Reference symbol L 1 indicates the baseline length of the short baseline length camera 12 , and reference symbol L 2 indicates the baseline length of the long baseline length camera 13 . The baseline length indicates the distance between the laser emitting position and the image-taking position using the reflected light of the emitted laser beam. The long baseline length camera 13 is positioned such that the baseline length of this camera 13 is longer than the baseline length of the short baseline length camera 12 .
Generally, in the light-section method, distance is determined using the principle of triangulation. In triangulation, a triangle is defined by connecting two reference points (whose positions are known) and any other third point, and the position of the third point is determined by measuring the angles of the triangle. According to the principle, the longer the distance between the known two points (which corresponds to the baseline length), the higher the accuracy of the measured distance.
As shown in FIG. 5, as the baseline length L 2 increases, angle D for determining the set (i.e., orientation) of the long baseline length camera 13 must be larger so as to properly take an image obtained by the reflected light of the “slit” light beam. However, the combination of the long baseline length L 2 and the large angle D makes the discrimination between each “slit” beam difficult.
On the other hand, for a shorter baseline length L 1 , angle E for determining the set (i.e., orientation) of the short baseline length camera 12 can be smaller. Therefore, the possible measurement range of the distance can be longer and each “slit” light beam can be easily discriminated. However, due to the above-explained reason, the accuracy of the measurement of the distance is lower in this case.
In the present invention, only advantageous features among the above features are used in order to accurately measure the distance and to control the walking action of the robot 1 . That is, objects are first measured in a broad range of distances by using the short baseline length camera 12 having a lower accuracy of the distance measurement, and after this rough estimation of the distance, the distance to each target object is determined by using the long baseline length camera 13 having a higher accuracy of distance, measurement.
This operation will be explained with reference to FIG. 6 . FIG. 6 is a flowchart showing the operation of the distance measurement.
In the first step S 1 , the image storing section 15 receives images taken by the short baseline length camera 12 and the long baseline length camera 13 and respectively stores these images. in the image memories 15 a and 15 b.
In the next step S 2 , the height estimating section 16 processes the data of the image taken by the short baseline length camera 12 , that is, the image data stored in the image memory 15 a , and detects the general form of the floor and obstacles on the floor. This detection is performed by determining the distance to each pixel which received the reflected light of the “slit” beam, based on the principle of triangulation.
In the next step S 3 , the action planning section 17 determines the action plan of the robot 1 in consideration of the floor and obstacles detected by the height estimating section 16 . In the action plan, specific actions are determined, such as “going around the right side of an obstacle”, “going straight and halting just before stairs which will appear in the path and going up the stairs”, or the like.
In the next step S 4 , the landing position determining section 18 determines the landing position of the raised leg of the robot 1 , by processing the data of the image taken by the long baseline length camera 13 , that is, the data stored in the image memory 15 b . Here, the landing position is determined with reference to the action plan and the results of obstacle detection performed by the height estimating section 16 . In order to determine the landing position, the stepping direction of the legs of robot 1 , the height of the raised leg, and the stride of the robot 1 must be determined, and in order to determine these parameters, distance data measured with high accuracy is necessary. Therefore, the data of the image taken by the long baseline length camera 13 is used. Accordingly, the accurate landing position of the raised leg can be determined. Additionally, even if some of the “slit” light beams are ineffective for taking an image, the general form of the floor and the obstacles are detected by referring to the image taken by the short baseline length camera 12 . Therefore, the images taken by the long baseline length camera 13 through the “slit” light beams can be effectively used for improving the measurement accuracy of the distance.
In the next. step S 5 , the leg control section 19 controls a drive section for driving the legs of the robot 1 so as to land the foot of the relevant leg at the landing position determined by the landing position determining section 18 .
As explained above, a plurality of light beams, each having a shape of a beam which passes through a slit, are simultaneously emitted, rough estimation of the distance is performed based on the image taken by the short baseline length camera 12 , and the distance is determined using the image taken by the long baseline length camera 13 with reference to the estimated results. Therefore, in a target area, highly accurate measurement of the distance is possible. In addition, the above plurality of light beams can be generated using a single light source (i.e., laser beam emitting section 21 ); therefore, no color image is necessary, and image data taken by non-color cameras whose brightness data are known or obtained are processed. In addition, the above plurality of light beams are generated using the diffraction grating 23 and beam diffusing lens 24 ; thus, the structure of the laser light source 11 can be simplified.
The baseline length L 1 in FIG. 5 is defined to be as short as possible as long as the distance (measurement) accuracy necessary for planning the action plan can be obtained. The angle E is defined to be as small as possible as long as the measurement area necessary for planning the action plan can be observed by the cameras used, that is, within the angle of view of the cameras.
The baseline length L 2 in FIG. 5 can be of a length necessary for determining the landing position of the leg of the robot 1 . The angle D can be of an angle necessary for observing an area determined based on the maximum stride of the robot 1 .
In addition, a stereoscopic image may be generated by processing the two images taken by the two cameras. In this case, a distance image is generated based on the stereoscopic image processing, and this distance image is used for determining the landing position. Accordingly, the accuracy for determining the measured distance can be further improved.
Additionally, the laser light source 11 is positioned between the short baseline length camera 12 and the long baseline length camera 13 . Therefore, the images obtained by the emitted “slit” beams can be efficiently taken. | A distance measuring apparatus is disclosed, which measures the entire image of a target object by employing a light-section method within a short time, without assigning any specific feature to light beams having a beam form obtained by passing through slits. The apparatus comprises a device for simultaneously emitting such light beams; first and second image taking devices for taking an image obtained by light reflected by the target object, where the distance between the first image taking device and the beam emitting device is relatively short while the distance between the first image taking device and the beam emitting device is relatively long; a section for estimating the distance to the target object based on the image taken by the first image taking device; and a section for determining the distance based on the estimated result and on the image taken by the second image taking device. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a trailer and more particularly to a trailer having a ramp tail.
Many types of trailers have been previously provided for transporting large equipment over the road. The equipment is normally loaded onto the trailer from the rearward end thereof. Folding ramps of the like have been provided at the rear end of the trailer to enable the equipment to move onto the trailer bed. One such type of trailer is disclosed in U.S. Pat. No. 4,372,727.
In most of the trailers which have folding ramp tails, a pair of axles are located at the rear of the trailer just forwardly of the hinge point of the ramp tail. In the conventional trailers having ramp tails, the rearwardmost axle must be located sufficiently forward enough so that the ramp tail may pivotally move downwardly. The requirement that the rear axles be located close together near the rear end of the main deck of the trailer and adjacent the hinge point of the ramp tail results in a less than desirable weight distribution for the trailer and can reduce the maximum payload that the trailer can carry.
It is therefore a principal object of the invention to provide an improved trailer having a folding ramp tail.
A further object of the invention is to provide a trailer having a pair of axles located at the rear of the trailer with one of the axles having the ability to be moved beneath the tail ramp during highway usage.
Yet another object of the invention is to provide a trailer of the type described which results in a better weight distribution capability for the trailer.
Yet another object of the invention is to provide a trailer of the type described which permits the trailer to carry a greater payload.
Another object of the invention is to provide a trailer which has the ability to spread the rear axles thereof.
These and other objects will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear perspective view of the trailer of this invention:
FIG. 2 is a side view as seen on lines 2--2 of FIG. 1:
FIG. 3 is a side view similar to FIG. 2 except that the rearwardmost axle has been slidably moved rearwardly with respect to the front axle:
FIG. 4 is a front perspective view of the slider assembly of this invention:
FIG. 5 is a front perspective view of a portion of the slider assembly and its relationship to the longitudinal beams of the trailer:
FIG. 6 is a topped elevational view of the trailer of this invention with the rear axle having been slidably moved rearwardly:
FIG. 7 is a sectional view as seen on line 7--7 of FIG. 6:
FIG. 8 is a sectional view as seen on line 8--8 of FIG. 6:
FIG. 9 is a sectional view as seen on line 9--9 of FIG. 6; and
FIG. 10 is a sectional view similar to FIG. 9 except that the rear axle has been slidably moved forwardly from the position of FIG. 9.
SUMMARY OF THE INVENTION
A trailer is disclosed which includes a main frame portion having rearward and forward ends with means at the forward end of the main frame portion for connection to a prime mover such as a truck or the like. A ramp tail is hingedly connected to the rearward end of the main frame portion and may be moved from a horizontal load carrying position to an inclined unloading and loading position. A first axle assembly including a suspension system is mounted on the main frame portion forwardly of the hinge point of the ramp tail. A second axle assembly including a suspension means is positioned rearwardly of the first axle assembly and is located approximately beneath the hinge point of the ramp tail when it is desired to pivot the ramp tail to is unloading/loading position. The second axle assembly and suspension system may be slidably moved rearwardly beneath the ramp tail during highway usage of the trailer thereby resulting in a better weight distribution for the trailer which permits the trailer to carry a greater payload. The fact that the second axle may be moved beneath the ramp tail during highway usage also ensures that the ramp tail will not inadvertently pivot or hingedly move downwardly during highway usage.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the numeral 10 generally designates the trailer of this invention including a main frame portion 12 having a powered ramp tail 14 pivotally secured thereto at 16. Ramp tail 14 has a flip tail 18 pivotally secured to the rearward end thereof as will be described in more detail hereinafter. Trailer 10 includes means at the forward end thereof for attachment to a prime mover such as a truck or the like.
As seen in FIG. 6, main frame portion 12 includes a pair of longitudinally extending I-beams 20 and 22 positioned at the center thereof. Main frame portion 12 also includes a pair of longitudinally extending frame members 24 and 26 at the sides thereof. The main frame portion 12 also includes a plurality of transversely extending frame members 28 which extend between the side frame members 24 and 26. Deck 30 is supported on the frame members 20, 22, 24 and 26 in conventional fashion.
The numeral 32 refers to a front suspension system which is mounted at the rearward end of the main frame portion 12 as illustrated in the drawings. Suspension system 32 is conventional in design and will not be described in detail for that reason.
The numeral 34 refers to a slider assembly including longitudinally extending frame members 36 and 38. Shaft 40 is secured to and extends between the forward ends of the frame members 36 and 38 and has rollers 42 and 44 mounted on the opposite ends thereof which are adapted to roll upon the inner top portions of the bottom flanges of frame members 20 and 22 respectively. Shaft 46 is secured to and extends between the rearward ends of frame members 36 and 38 and has rollers 48 and 50 mounted on the outer ends thereof. Suspension system 52 is mounted on the frame members 36 and 38 for movement therewith and is identical to the suspension system 32. Hydraulic cylinder 54 is connected at its base end to frame member 28 at 56 and is connected at its rod end to frame member 58 which is secured to and extends between frame members 36 and 38 as illustrated in FIG. 4. Extension of the hydraulic cylinder 54 causes the slider assembly 34 and the suspension system 52 to be moved forwardly with respect to the main frame portion 12.
Ramp tail 14 includes a pair of longitudinally extending center beams 60 (not shown) and 62, the forward ends of which are pivotally connected to the rearward end of the main frame portion 12 at 16. Inasmuch as the center beams 60 and 62 are identical, only center beam 62 will be described in detail. The underside of the bottom flange of the center beam 62 includes an upwardly extending portion 64 at its rearward end and a portion 66 forwardly thereof which extends upwardly and forwardly therefrom as seen in FIG. 9. A horizontally disposed portion 68 is provided forwardly of portion 66 and an inclined portion 70 is provided forwardly of horizontally disposed portion 68. Roller 50 is adapted to roll upon the underside of the bottom flange of center beam 62 to cause the ramp tail 14 to be pivotally moved with respect to main frame portion 12 as hydraulic cylinder 54 is retracted and extended.
As seen in FIG. 9, when the slider assembly 34 is completely extended, roller 50 is positioned beneath the forward end of inclined portion 64 to maintain the ramp tail 14 in a horizontal position. As hydraulic cylinder 54 is retracted from the position of FIG. 9 to the position of FIG. 10, roller 50 rolls upon portion 66 so that the ramp tail 14 pivotally moves downwardly from the position of FIG. 9 towards the position of FIG. 10. The hydraulic cylinder 54 is retracted until the roller 50 is positioned sufficiently forwardly enough with respect to the center beam 62 so that portion 64 of center beam 62 may rest upon the ground or other supporting surface. Roller 48 similarly rolls on the underside of centerbeam 60. When the roller 50 is in the position of FIG. 9, ramp tail 14 cannot pivotally move downwardly into ground engagement.
Flip tail 18 normally hangs in the position seen in FIG. 9 when the trailer is being moved over the road so as to serve as a bumper. When it is desired to move the ramp tail 14 downwardly into ground engagement, the air actuator assembly 72 automatically pivotally moves the flip tail 18 from the position of FIG. 9 to the position of FIG. 10 so that the flip tail 18 forms an extension of the deck of ramp tail 14.
When the ramp tail 14 is in the position of FIG. 3, the rear suspension system 52 is "spread" a considerable distance rearwardly of the suspension system 32 thereby achieving a better weight distribution for the load on the trailer than when the suspension systems are closely positioned as illustrated in FIG. 2. When the slider assembly 34 has moved the rear suspension system 52 to the position of FIG. 3, a greater amount of weight may be placed on the ramp tail than otherwise possible and the positioning of the suspension system 52 prevents the ramp tail 14 from inadvertently moving downwardly as the trailer is moving over the road.
When it is desired to either load the trailer or unload the trailer, hydraulic cylinder 54 is retracted so that the slider assembly 34 is moved forwardly relative to main frame portion 12. The retraction of cylinder 54 causes the slider assembly 34 to move forwardly with the rollers 42 and 44 rolling upon the bottom flanges of the frame member 20 and 22. As seen in FIG. 5, frame members 20 and 22 are provided with elongated angles or retainers 74 and 76 to prevent upward movement of the rollers 42 and 44 relative to the frame members 20 and 22.
As the retraction of the cylinder 54 continues, rollers 48 and 50 roll upon the undersides of the center beams 60 and 62 so that the ramp tail 14 may pivotally move from the position of FIG. 9 towards the position of FIG. 10. Hydraulic cylinder 54 would be retracted until the rearward end of the ramp tail 14 is moved into ground engagement. When the ramp tail 14 is in its lowered position, the trailer may be loaded or unloaded. When it is desired to move the trailer over the road, slider assembly 34 is again moved rearwardly relative to main frame portion 12.
Thus, it can be seen that the invention accomplishes at least all of its stated objectives. | A trailer comprising a main trailer portion having a ramp tail hingedly secured to the rearward end thereof. A first axle and suspension system is positioned beneath the main portion of the trailer forwardly of the hinge point of the ramp tail. A second axle and suspension system is positioned rearwardly of the first axle and is located beneath the hinge point of the ramp tail when it is desired to pivotally move the ramp tail. During highway usage, the second axle may be slidably moved beneath the ramp tail so as to increase the distance between the two axles. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional patent application Ser. No. 61/961,401, filed 2013 Oct. 15 by the present inventor.
BACKGROUND—PRIOR ART
[0002] The following is a tabulation of some prior art that presently appears relevant:
[0000]
U.S. Patents
Patent Number
Kind Code
Issue Date
Patentee
3,986,787
A
1976 Oct. 19
Mouton
4,717,831
A
1988 Jan. 5
Kikuchi
5,366,341
A
1994 Nov. 22
Marino
7,075,190
B1
2006 Jul. 11
Lomerson
7,200,879
B2
2007 Apr. 10
Li
7,378,750
B2
2008 May 27
Williams
7,492,054
B2
2009 Feb. 17
Catlin
7,999,444
B2
2011 Aug. 16
Sunaga
8,002,974
B2
2011 Aug. 23
Noling
8,080,893
B2
2011 Dec. 20
Lin
8,102,071
B2
2012 Jan. 24
Catlin
20140165712
A1
2014 Jun. 19
Zeng
[0003] This invention relates to forces of nature being transformed by rotary motion into energy that can be readily available for consumption. Much of the energy consumed by entities require hydrocarbon fossil fuel sources. Utilizing these fuels emit elements into the environment that have created an alert that requires the reduction of these fuel emissions. Accordingly, the nonrenewable nature of these fuels has guided industry and public opinion that the field of technology is to seek alternative sources. The search of prior art has revealed this activity in the field of technology.
SUMMARY
[0004] It is the object of this invention to provide useful energy by utilizing multiple forces of nature simultaneously or separately. This invention accumulates each of these forces as they are available by transporting a portion of the water they influence into a central containment area. A series of mechanical parts jointly fitted together in synchronized motion is the method by which it functions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a front view of the impeller wheel connected to the spiral elongated screw pump with the gimbal and dispersion tray.
[0006] FIG. 2 is a side view of the impeller wheel, dispersion tray, inlet conduit, and buoyancy devices.
[0007] FIG. 3 is a top view of the impeller wheel, dispersion tray, spiral elongated screw pump cylinder and buoyancy devices.
[0008] FIG. 4 is a side view of the impeller wheel, dispersion tray, conduit and buoyancy devices in a reservoir.
[0000]
Drawings-Reference Numerals
1
impeller wheel
2
horizontal shaft
3
bearings
4
spiral elongated screw pump cylinder
5
center shaft
6
upper bearing
7
gimbal
8
spiral conduit
9
lower end
10
upper end
11
U shape reservoir channel
12
anti-reverse brake pivot system
13
dispersion tray
14
inlet conduit
15
partition
16
buoyancy devices
17
flexible conduit
18
water level
19
rises
20
embankment
21
reservoir
22
rise
DETAILED DESCRIPTION OF THE INVENTION
[0009] There are no structural supports illustrated in this detailed description. In FIG. 1 the impeller wheel 1 is on the horizontal shaft 2 supported by the two bearings 3 . The spiral elongated screw pump cylinder 4 center shaft 5 that extends toward both ends, further at the upper end, of the spiral elongated screw pump cylinder 4 and set at an angle by the upper bearing 6 is attached to the impeller wheel horizontal shaft 2 by the gimbal 7 that is housed inside the lower end of the spiral elongated screw pump cylinder 4 . The spiral conduit 8 begins at the edge of the lower end 9 of the spiral elongated screw pump cylinder 4 and spirals around the outside one revolution in equal form to the edge of the upper end 10 of the spiral elongated screw pump cylinder 4 . The upper edge of the U shape containment area channel 11 is located immediately, without contact, beneath the upper end of the spiral conduit 8 . The lower edge of the U shape reservoir channel 11 is sufficiently above the elevation of the center of the impeller wheel horizontal shaft 2 . The anti-reverse brake pivot system 12 is attached to the upper end of the spiral elongated screw pump cylinder 4 center shaft 5 . The dispersion tray 13 is specifically located immediately, without contact, at the outer edge of the impeller wheel 1 between the impeller wheel 1 sides above the horizontal shaft 2 and below the top of the impeller wheel 1 and is attached to the upper end of the inlet conduit 14 .
[0010] In FIG. 2 each partition 15 , equally spaced with the other is set perpendicular between the sides of the impeller wheel 1 beginning less than flush, not illustrated here, with the circumference edge of the impeller wheel 1 sides and extend to the impeller wheel horizontal shaft 2 in FIG. 1 . In FIG. 4 the impeller wheel 1 , dispersion tray 13 , inlet conduit 14 , flexible conduit 17 and the buoyancy devices 16 are specifically located in a buoyancy system.
[0011] In FIG. 4 , as the water level 18 rises 19 caused by the tide, precipitation, waves, surge and other means being controlled by an embankment 20 , it is allowed to flow into the inlet conduit 14 through the embankment 20 and into a reservoir 21 . The arrows in FIG. 4 illustrate the direction of the flow of water during the operation of the waterfall apparatus. The gravity influenced water flows into the inlet conduit 14 and out of the dispersion tray 13 causing the impeller wheel 1 to rotate by the weight of the water that collects between each corresponding partition 15 thus rotating the spiral elongated screw pump cylinder 4 and the spiral conduit 8 in FIG. 1 . The lower end of the spiral conduit 8 captures a measured amount of water from the reservoir 21 in FIG. 4 . The captured water is elevated to the upper end 10 of the spiral conduit 8 in FIG. 1 by the rotation and allows it to flow into the U shape containment area channel 11 .
[0012] As the impeller wheel 1 in FIG. 4 rotates, the water flows from between each corresponding partition 15 into the reservoir 21 causing the water level in the reservoir 21 to rise 22 . The flexible conduit 17 allows the buoyancy devices 16 to float on the surface of the reservoir 21 in a stable form, keeping the impeller wheel horizontal shaft 2 in FIG. 1 and the dispersion tray 13 in FIG. 4 at a specified distance above the reservoir 21 water surface as the level rises. The spiral elongated screw pump cylinder 4 center shaft 5 in FIG. 1 pivots at the anti-reverse brake pivot system 12 enabling the buoyancy devices 16 in FIG. 4 to float on the surface of the reservoir 21 in a stable form as the water level rises. The brake in the anti-reverse brake pivot system 12 in FIG. 1 functions as a ratchet allowing the spiral elongated screw pump cylinder 4 center shaft 5 to rotate in one direction, preventing the gravitational force of the water in the spiral conduit 8 to rotate it in the opposite direction.
[0013] In FIG. 2 the design and number of partitions 15 are determined by the required function. The less than flush, not illustrated here, short distance from the outer edge of the partition 15 in FIG. 4 and the circumference edge of the impeller wheel 1 sides in FIG. 1 is sufficient to prevent the water from overtopping the sides as it flows from the dispersion tray 13 , then horizontally in both directions along the impeller wheel horizontal shaft 2 and impacts the impeller wheel 1 sides. The dispersion tray 13 is located as to rotate the spiral conduit 8 in the direction that elevates the captured water. The elevation of the U shape containment area channel 11 is increased by the diameter, length or angle of the spiral elongated screw pump cylinder 4 . The length determines multiple revolutions of the spiral conduit 8 around the outside. Increasing the impeller wheel 1 accordingly, provides the necessary force to implement the correct balance at the gimbal 7 to rotate the spiral elongated screw pump cylinder 4 .
[0014] The impeller wheel horizontal shaft 2 and dispersion tray 13 in FIG. 1 is set at a minimum distance above the reservoir 21 water surface in FIG. 4 to minimize the head of the two water levels. The water is released, when necessary, from the reservoir 21 through a conduit equipped with a one-way flow system, not illustrated.
[0015] In FIG. 1 the water in the containment area, which is not illustrated here, that is derived from the U shape containment area channel 11 is released in a timely manner to produce useful energy. | A rotary pump that utilizes falling water to produce useful energy. The pump is a conduit in a spiral form mounted on an axis that is set at an angle whereby when rotated, water flows into the inlet end of the conduit and is transported to an elevation. The conduit is powered by an impeller wheel that rotates by falling water. | 8 |
BACKGROUND OF THE INVENTION
1. Field of Invention:
The present invention relates generally to shelters and, more specifically, to a new and improved temporary shelter for multiple homeless inhabitants.
2. Description of the Prior Art:
As a result of various meteorlogical or geological disasters such as hurricanes, tornadoes or earthquakes, numerous homes or multiple-unit dwellings may be damaged or otherwise rendered uninhabitable. In addition, with the well-publicized increase in the number of "homeless" persons in the United States, there has been a corresponding increase in the need for an inexpensive way to shelter these persons. Construction of conventional low-cost housing in response to such demands has its limitations. Construction of multi-unit dwellings using conventional techniques usually requires a few months to a year for completion. While pre-fabrication processes have drastically reduced this construction time, current structures still require a relatively large foundation unit, such as a level concrete slab or fabricated floor. This inhibits the disassembly of the construction and usually requires relatively large parcels of real estate which may be unobtainable in the highly commercialized and valuable areas that the homeless often inhabit.
In addition, the construction of these multi-unit dwellings often requires a capital investment which communities are reluctant to make for non-revenue generating transient inhabitants. Indeed, this transiency further contributes to such reluctance on the part of the community, since there is no guarantee that the demand for such housing will be at the same levels when the construction is completed, and any construction of such housing may encourage an influx of more homeless people.
Alternatively, less permanent structures have their own limitations. Allowing the homeless to construct their own haphazard shelters can create an eye-sore and increase local community opposition. Generally, these structures are constructed of whatever material is available, most commonly canvas, cardboard or wood. These structures usually do not conform to community building codes enacted for safety and sanitary reasons. As a result, these structures are susceptible to the elements and tend to prevent their occupants from staying dry in inclement weather. These construction materials also tend to resist cleaning and are susceptible to vandalism. A damp, unclean environment is prone to breed vermin, unsanitary conditions and disease. As a result, many communities are reluctant to allow the location of such developments within their community.
Thus, those who have been involved in the development of shelter structures have long recognized the need for an improved structure which provides an inexpensive, easy to construct, warm and dry environment. The present invention fulfills all of these needs.
SUMMARY OF THE INVENTION
Briefly, and in general terms, the present invention provides a new and improved temporary shelter which is inexpensive, quickly and easily disassembled or assembled, and easily maintained clean, warm and dry.
By way of example, and not necessarily by way of limitation, the shelter structure of the present invention provides a plurality of individual compartments which are suspended by mounting them upon a support structure. Each individual compartment is constructed for easy cleaning and maintaining the inhabitants in a warm and dry environment.
In one preferred embodiment, the shelter structure of the present invention includes a base and structural support members extending generally vertically upwards therefrom. A plurality of horizontal cross-braces extend between said vertical members to support and mount a plurality of hollow individual compartment members thereon. Alternatively, the structural support members may be at an angle other than vertical, e.g., triangular in configuration, or may be centrally located with the cross-braces extending across the support members. Each of the compartment members defines a hollow interior and includes a sloping floor and drain. A longitudinal side opening allows access to the interior. A light box is mounted adjacent one longitudinal end of the compartment to illuminate its interior. The light box is a compartment containing a fluorescent or incandescent light that serves a number of purposes, including providing light and heat for the interior and light for a sign, advertising, or other identification if required. A power source is provided for the light box and for additional heating or electrical requirements.
From the above description it can be readily seen that the present invention provides a new and useful structure for the temporary housing of persons in an inexpensive, temporary, clean and dry environment. Other features and advantages of the present invention will become apparent form the following detailed description, taken in conjunction with the accompanying drawings, which illustrate by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective drawing of a temporary shelter structure incorporating the novel features of the present invention;
FIG. 2 is a front elevational sectional view of the present invention taken substantially along the line 2--2 of FIG. 1;
FIG. 3 is a fragmentary side elevational view of the present invention taken substantially along the lines 3--3 of FIG. 1;
FIG. 4 is an enlarged, fragmentary sectional side elevational view of the present invention, taken substantially from the circle 4 of FIG. 3;
FIG. 5 is an enlarged, fragmentary side elevational sectional view of the present invention, taken substantially along the lines 5--5 of FIG. 2; and
FIG. 6 is a fragmentary side elevational view of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the exemplary drawings, an improved temporary structure constructed in accordance with the present invention is provided for housing a plurality of persons inexpensively in a clean and dry environment. In addition, the temporary shelter of the present invention, while avoiding the limitations present in more permanent structures, provides an easy to clean, dry and vandal-resistant structure.
Referring to FIG. 1, the improved temporary shelter structure 10 of the present invention includes a structural support 12. Individual compartment members 14 are mounted upon the support 12 and formed to facilitate a dry but easily cleaned environment. A power source 16 is electrically connected to a light box 18 for illuminating and heating each individual compartment 14.
Referring to FIG. 2, the support 12 includes a base or foundation 22 placed on or below the ground level. This base or foundation may be in the form of a concrete or cement platform or merely cylindrical holes dug in the ground and filled with a cement or concrete material. Alternatively, the base may be a portable or moveable structure that includes means to mount the vertical support and provide a stable base for the housing unit. While a uniform platform extending beneath the entire shelter 10 may provide substantial stability, the base 22 need only preclude the settling or tipping over of the temporary shelter 10. For example, holes having a diameter of about two feet and a depth of about three feet filled with a foundation material are adequate. A base 22 so configured facilitates removal of the base 22 from the ground when the housing unit is no longer needed.
FIG. 2 also illustrates a plurality of generally vertical support members or legs 24 extending upward from the base 22. Each individual leg 24 extends above ground about eight to about nine feet while being spaced laterally apart from each other about four and one-half feet. While the support members 24 can be of any strong construction material, two by four inch (0.125 wall) structural steel members may be used. Extending transversely between the plurality of the vertical support members 24 is a plurality of generally horizontal cross-braces 30. For example, about four to about five foot lengths of two by four inch structural steel members may extend laterally between the generally vertical support members 24. A first plurality of cross-braces 31, 32 and 33 are mounted on a first pair of vertical supports 26 at a first, second and third vertical levels above the ground. The lowest cross-brace 31 can be spaced about two inches above the ground. Cross-braces 31, 32 and 33 are spaced apart from each other a sufficient distance to receive the compartment member 14 therebetween, for example about two-feet, six-inches apart. The plurality of cross-braces 30 are joined or mounted to the vertical support members 24 by conventional means, for example, by conventional welding or bolt means. Those skilled in the art of structural design will appreciate that many alternative structures may be configured to that described and illustrated. For example, the vertical support members may be replaced by members at an angle to the vertical or the members may be centrally located with the cross-braces 30 extending across them.
Still referring to FIG. 2, the plurality of individual compartment members 14 are mounted upon the cross-braces 30. While any desired number of compartment members 14 can be used, in one preferred embodiment, there are six compartment members 14 mounted longitudinally upon the cross-braces 30, a pair of compartment members 14 upon each plane defined in part by the corresponding individual cross-braces 31, 32 and 33. Each compartment member 14 can be formed of a double-walled structural fiberglass cylinder 36, having a first and second end walls 42 and 44 with a generally cylindrical side wall 46 extending therebetween to define a hollow interior 49. Structural ribbing 47, positioned longitudinally along the side wall 46 to engage or abut with the cross-braces 30, extends downward from a bottom portion 48 of the cylindrical wall 46. Each compartment member 14 is sized to comfortably receive a human being, and, for example, may have a radius of about one foot to about one foot-six inches and be about six feet, six inches in length.
Still referring to FIG. 2, a longitudinal entrance opening 50 is defined within a outward facing portion of the side wall 46 to allow access to the compartment member's hollow interior 49. The entrance 50 can be of any shape or size enabling access to the interior. For example, in the preferred embodiment, a generally rectangular opening about three-feet, six-inches long and about one-foot, six-inches in width is formed within the sidewall 46. An overhanging top edge 52 of the opening 50 is formed to project laterally outward beyond a bottom edge 54 about six inches downward from the apex of the compartment member 14. The bottom edge 54 of the opening 50 is formed inward about two inches from the most lateral projection of the overhanging top edge 52 by a generally vertical wall portion 56. The vertical wall portion 56 is formed by altering the curvature of the bottom portion of the compartment member 14, for example, by a bend 58 having a curvature of about a three inch radius. As a result, the bottom edge 54 is positioned inward relative the top edge 52 and extends vertically upward.
As best shown in FIGS. 3 and 4, formed in the second end wall 44 of the compartment member 14 is a window 60 for transmitting light into the interior 49 of the compartment 14 from the light box 18. In the preferred embodiment, a one-inch thick plexiglass plug 61 is fitted flush with the end wall 44. The window 60 is formed in the second end wall 44 along the central longitudinal axis of each compartment member 14. Adjacent to window 60 is the light box 18, having a fluorescent lamp 64, discussed more fully elsewhere in this application.
While conventional mounting means such as various bolt assemblies can be used, aluminium internal threaded, internal hex stadium seat-type bolt assemblies 68 as best shown in FIG. 5 may be used to mount the compartment members 14 to the cross-braces 30. This type of bolt assembly substantially inhibits disassembly by unauthorized persons, a strong possibility considering the intended use of the housing unit and its likely location.
Referring now to FIG. 6, the structural support 12 includes a first and second pair 70 and 72 of vertical support members spaced longitudinally apart from one another. In the preferred embodiment, the vertical support members 24 are spaced apart from each other a distance, for example about four and one-half feed, to provide a stable support for the compartment members 14. The horizontal cross-braces 30 are correspondingly vertically positioned to extend laterally between the vertical support members 24 to and define the generally horizontal planes upon which the compartment members 14 are positioned.
In addition, as best shown in FIG. 6, the bottom portion 48 of the compartment member 14 is formed with a slight downward slope within its top surface 75 along its longitudinal axis towards a first end 76 of the compartment member 14. A slope of about 1/8 of an inch drop per foot of length is adequate. Formed within the bottom portion 48 of the compartment member 14, adjacent the first end 76, e.g., at the lowest point of the sloping top surface 75 of the bottom portion 48, is a cut-out or drain 80 of about four inches in diameter. In the preferred embodiment the drain 80 is formed in an end substantially opposite from the window 60. While any conventional construction material may be used, the compartment members 14 may advantageously be constructed of double-walled fiberglass. By this construction, each individual compartment member 14 are readily washable and maintainable in a clean and sanitary condition. Furthermore, each individual compartment member 14 is generally more resistant to the effect of weather and less likely to conduct heat to the outside of the container in inclement weather.
Extending longitudinally between the generally vertical support members 24, i.e., between the first and second pairs of vertical support members 70 and 72, are longitudinal support members 84. These longitudinal support members 84 extend from the vertical support members 24 outward at a first end of the support structure 12 to extend adjacent the second end 44 of the compartment member 14, adjacent the window 60.
Mounted to the longitudinal support members 84 is the light box 18 which provides lighting to the hollow interior of the compartment member 14 through the window 60. A standard 4-foot, 6-inch width, by 6-foot, 3-inch height bus stop billboard box can be used and mounted to the ends of the longitudinal support members 84 and thus positioned adjacent or juxtaposed against the windows 60 formed within the second end wall 44 of the compartment members 14. A second plurality of generally vertical support members 85 may extend upward from a base 22 to support the light box 18. Fluorescent or incandescent lighting can be used, not only to provide light but also to generate indirect heat to the interior of the compartments 14. Electrically connected to the light box 18 and mounted atop the vertical support members 24, above the compartment member 14, is the power source 16. While any self-contained power source may be used, nickel-cadium electrical storage batteries (not shown) may provide an electrical power source 16 for the light box 18 and for any additional heating elements (not shown) within the temporary shelter structure 10 themselves. A solar collector 86 is electrically connected through electrical conduit 88 to the light box 18 and may also provide power for electrical outlets (not shown) adjacent each particular compartment member 14. By incorporating the light box 18 into the structure of the shelter 10, commercial advertisements may be solicited to help reduce the cost of building and supplying such temporary shelters, electrical power can be provided to maintain the individual compartments warm and dry, and the public screened from the shelters 10, reducing the unsightliness of the local environment. As an alternative to the solar power described, a local source of commercial power may also be used if it is readily available and practical to use. Such local power could be supplied, for instance, by appropriately secured nonstandard plug terminals located conveniently in locations that are likely to accomodate such structures from time to time. For instance, such terminals may be located in the inner city in cold climates for use in the winter months when the homeless are exposed to inclement weather.
From the above, those skilled in the art will appreciate that the present invention represents a new and useful structure for transients or other displaced persons that embodies many advantages over previously available temporary structures. It will also be apparent that from the foregoing that, while particular forms of the invention have been illustrated and described, various modifications can be made without departing from the spirit and the scope of the invention. Accordingly it is not intended that the invention be limited, except as by the appended claims. | A temporary shelter including a support structure extending upwardly from a base and hollow compartment members mounted upon the support structure, the hollow compartment further including an opening and a liquid drain. A window formed within the compartment walls transmits light from a light box mounted adjacent thereto and electrically connected to a power source. | 4 |
This application is a continuation of application Ser. No. 08/454,198, filed Jun. 19, 1995 now abandoned which is a 371 continuation of PCT/DE93/01210, filed Dec. 17, 1993.
FIELD OF THE INVENTION
The present invention relates to a device for adjusting a cutter bar for a cutting cylinder of a rotary printing press.
DESCRIPTION OF THE PRIOR ART
In connection with a cutting and collecting device for rotary printing presses, it is known from DE-PS 6 71 790 to employ a cutting cylinder which cooperates with a collecting cylinder having three groove bars on its circumference. The device is used for the continuously changing cutting and for collection of two cut pieces which are slightly different in length and which are intended to have equal edge lengths after mutual transverse folding. For this reason, the two cutters of the cutting cylinder are disposed at an angle of slightly more and again slightly less than 180° with respect to each other in the circumferential direction.
A device for adjusting a cutter bar of a cutting cylinder in the folding unit of a rotary printing press is known from EP 03 64 864 A2. Different cutting lengths of the cut pieces can be adjusted since the cutting cylinder with two cutters disposed on the circumference consists of an inner and an outer cylinder, both of which can be adjusted in the circumferential direction. This is accomplished by means of an additional second wheel train disposed on the press frame. In this case, the extra outlay of press elements as well as an increase in the structural volume is disadvantageous.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a device for adjusting the two cutter bars of a cutting cylinder of a folding unit.
The device for adjusting cutter bars on a cutting cylinder in accordance with the present invention is usable to accomplish the transverse cutting of a paper web train prior to its entry into a folding apparatus. The cutting cylinder can be switched between collection and no collection. The cutter bars are movable selectively toward or away from each other about the circumference of the cutting cylinder while remaining parallel to the axis of rotation of the cutting cylinder. This allows the cutting cylinder to produce signatures having the same or differing lengths. A groove and a cooperating pin engaging the groove may be provided as the adjustment device for the cutter bars on the cutting cylinder. The groove and the pin are disposed so they perform a relative movement with respect to each other.
The following advantages in particular are attained by the invention. The structural size of the device is not increased by an actuating element for adjusting the cutter bars disposed outside of the lateral frame. The device can be easily operated from the operating side of the press and has cost-effective structural elements. In the course of a change of the folding unit from dual production to collective production and vice versa, the device can be easily reset from long-long cutting to long-short cutting. A continuous adjustment is also possible.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in detail by means of several exemplary embodiments. The associated drawings show in:
FIG. 1, a top view of a cutting cylinder;
FIG. 2, a cross-sectional view taken along line II--II of FIG. 1;
FIG. 3, an enlarged representation of a portion of a cutter bar of FIG. 2;
FIG. 4, a partial cross-sectional view taken along line IV--IV of FIG. 2, represented turned by 90°;
FIG. 5, a second preferred embodiment of a drive for the lifting spindle of FIG. 1;
FIG. 6, a third preferred embodiment of a drive for the lifting spindle analogous to a representation of FIG. 4;
FIG. 7, a fourth preferred embodiment of a drive for the lifting spindle analogous to a representation of FIG. 4;
FIG. 8, a top view of a cutting cylinder with fifth and sixth preferred embodiments of a drive for a device for adjusting a cutter bar;
FIG. 9, a section IX--IX of FIG. 8 with the fifth preferred embodiment;
FIG. 10, a section X--X of FIG. 8 with the sixth preferred embodiment;
FIG. 11, a top view of a cutting cylinder with a seventh preferred embodiment of a device in accordance with the present invention;
FIG. 12, a section XII--XII of FIG. 11;
FIG. 13, a section XIII--XIII of FIG. 11;
FIG. 14, a top view of a cutting cylinder with an eighth preferred embodiment of a device;
FIG. 15, a section XV--XV of FIG. 14;
FIG. 16, a partial section XVI--XVI of FIG. 14;
FIG. 17, a top view of a cutting cylinder with a ninth preferred embodiment of a device;
FIG. 18, a section XVIII--XVIII of FIG. 17;
FIG. 19, a partial section XIX--XIX of FIG. 17;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A cutting cylinder 1--as represented in FIG. 1--is seated by means of its axle journals 2, 3 in lateral frames, of which only the left lateral frame 4 is shown. The axle journal 2 is seated in a cylindrical roller bearing 6, which is designed as a movable bearing. A lifting spindle 8 is disposed in a centered bore 7 of the cutting cylinder 1, as seen in FIG. 2 and is movable over a lift length "a" in the axial direction. Lifting spindle 8 is connected outside of the axle journal 2 and on the far side of the left lateral frame 4, with a manipulator, for example a hand wheel 12, via a coupling 9 and a threaded spindle 11. The threaded spindle 11 extends through a threaded bore 13 of a pillow block 14 fixed on the frame 4. The cylindrical roller bearing 6 as well as the pillow block 14 are disposed fixedly to the frame by means of screws 15, for example cap screws. The bore 7 has an appropriate fit, so that the seating play between the lifting spindle 8 and the bore 7 is minimized.
The cutting cylinder 1 has--as represented in FIG. 2--two grooves or channels 16, 17 with bottoms 18, 19 on its circumference. These first and second grooves or channels 16 and 17 are diametrically opposed to each other and extend in a direction parallel to an axis of rotation of cutting cylinder 1. Cutter bars 21, 22 are disposed in these channels 16 and 17. The first and second cutter bars 21, 22 respectively each comprise a guide strip 23 or 24, disposed on the bottom 18, 19 of the groove or channel 16, 17, and having a rectangular cross section. A cutter insertion bar 27, 28 which each is supporting in an axis-parallel direction respectively one cutter 29, 30 projecting from the cutter insertion bar 27, 28, is frictionally and interlockingly connected with the guide strip 23, 24 by means of screws 26, for example cap screws. The guide strips 23, 24 can be embodied in one piece together with the cutter insertion bars 27, 28.
As may be seen FIGS. 2 and 4, the portion of the lifting spindle 8 inside the cutting cylinder 1 has two bores 32, 33 extending in a radial direction, through which first and second stay bolts or pins 34, 35 respectively extending in the radial direction are disposed on both sides.
A pair of diametrically extending first and second channels 37, 38 in which the stay bolts 34, 35 are situated, extend from the centered bore 7 in the radial direction. The stay bolts 34, 35 have outer ends which engage grooves 39, 40 having round ends and which grooves 39, 40 are arranged in the guide strips 23, 24 of the cutter bars 21, 22. The grooves 39, 40 can be embodied as elongated holes.
The grooves 39, 40 in the guide strips 23, 24 extend at an angle α of a size in the range between 2° to 10° in respect to an axial center line 42 of the cutting cylinder 1--as shown in FIG. 2. The illustrations represented in FIGS. 1 to 3 show the cutters 29, 30 in the position of "no collection production", i.e. the cutters extend in alignment with the center lines 42. Screws 43 extend in the axis-parallel direction in respect to the stay bolts 34, 35 and are disposed in threaded bores on both sides of the groove 16, 17 in the jacket surface of the cutting cylinder 1. These screws 43 are provided to reduce the seating play of the guide strips 23, 24 fastened to the cutter bars 21, 22, and to press a sliding block 46, via a compression spring 44 indicated in FIGS. 2 and 3, against the guide strip 23, 24, so that the guide strip 23, 24 is pressed against the bottom 18, 19 of the groove 16, 17.
The sliding blocks 46 can be made of hardened steel or preferably of brass, so that no wear occurs between the sliding blocks 46 and the guide strips 23, 24. The sliding blocks 46 are pressed against the guide strips 23, 24 with an amount of pressure which is slightly greater than the centrifugal forces acting in the opposite direction on the cutter bars 21, 22 when the cutting cylinder 1 rotates.
The coupling 9 is disposed between the lifting spindle 8 and the threaded spindle 11 and consists of a two-piece bearing housing 48, 49 connected by means of screws 47. This two piece bearing housing 48, 49 constituting the stator, whose first element 48 is frictionally and interlockingly connected with the threaded spindle 11. The first end of the lifting spindle 8 extending from the axle journal 2 of the cutting cylinder 1 is seated in the interior of the bearing housing 48, 49 in a rolling bearing 51, for example an axial roller bearing 51. This first end of lifting spindle 8 is kept in place by a screwed-on cover plate 52. The lifting spindle 8 rotates along with the rotation of the cutting cylinder 1. The coupling 9, with its two-piece bearing housing 48, 49 as well as the threaded spindle 11 or stator, is fixedly connected with the first bearing housing element 48 to remain fixed to the frame and acts as a drive for the stay bolts.
If it is now intended to switch the cutters 29, 30 from "no collection production" to "collection production", in which two cut pieces of different length are being created, the lifting spindle 8 is shifted in the axial direction of the arrow B by an amount "a" by turning the hand wheel 12 in a counterclockwise direction. This is shown by means of the dashed representation of the hand wheel 12 in FIG. 1, which had been moved by the amount "a" in the direction B. A circumferential movement of both of the cutter bars 21, 22 disposed in the grooves or channels 16, 17 by an amount or displacement "c" of approximately 2.5 mm both in the direction of the arrow D is performed due to the axial movement of both stay bolts 34, 35 along the center line 42, also in the direction B. This circumferential movement of the two cutter bars 21 and 22 is a result of the grooves 39, 40 with round ends extending obliquely at an angle α in respect to the centerline 42. Cut pieces are created by means of this circumferential shifting of both cutter bars 21 and 22 which have a cut length of -2·c on both sides, as well as cut pieces of a cut length of +2·c. The shifting of the two cutter bars 21 and 22, both in the circumferential direction D results in unequal circumferential spacings of the two cutter bars 21 and 22 with respect to each other. The two cutter bars 21 and 22 will no longer be diametrically opposed. Instead, a first arcuate distance between the two will be less than 180° while a second arcuate distance around the cylinder 1 will be more than 180°.
A second preferred embodiment of a drive for the lifting spindle 8 in accordance with FIG. 1 is shown in FIG. 5. The lifting spindle 8 is connected to a piston rod 57 of a double-acting pneumatic work cylinder 58 through a coupling 53 consisting of a two-piece bearing housing 54, 55 connected by screws 47.
This work cylinder 58 is fastened via a pillow block 59 by respective screws 15 to the left lateral frame 4. Analogous to the coupling 9, in the coupling 53 the end of the spindle lifting 8 extending from the axle journal 2 of the cutting cylinder 1 is seated in a rolling bearing 51, for example an axial roller bearing, and is held by means of a screwed-on cover plate 52, so that when the cutting cylinder 1 rotates, the lifting spindle 8 rotates along with it, while the coupling 53 consisting of its two-piece bearing housing 54, 55, as well as the piston rod 57 fixedly connected with the first bearing housing element 54, remain fixed to the frame. The piston rod 57 is fed through a bore 61 of the pillow block 59. The work cylinder 58 has two connectors 62, 63 for compressed air which are connected via valves, not shown, with a compressed air installation. The ends of the stay bolts 34, 35 pointing in the direction of the jacket surface of the cutting cylinder 1 have been identified by 65, 66; 67, 68 as may be seen most clearly in FIG. 4.
A third preferred embodiment of a drive for the lifting spindle 8, which supports the stay bolts 34, 35 and which is movable in an axial direction, is seen in FIG. 6. In this third embodiment the lifting spindle 8 terminates at an electric linear drive or linear motor 69 which motor 69 is disposed in a hollow chamber 71 of the cutting cylinder 1 and exerts a lifting force in the axial direction on the lifting spindle 8. Such a linear motor 69 is described in a brochure of Lintrol Systems (U.K.) Ltd, Loughborough, England. To provide an improved accessibility to the hollow chamber 71, the axle journal 2 can be frictionally and interlockingly connected by means of machine bolts 72 with the front face of the cutting cylinder 1. The transmission of the control pulses as well as the power current for the linear motor 69 can take place via known electrical collector ring systems connected with the axle journals 2, 3. However, it is also possible to transmit the electrical drive energy, commands and pulses in a contactless manner to the rotating cutting cylinder 1. This transmission takes place in such a way that a secondary coil 74 with a secondary electronic device is disposed, for example on an axle journal 2 of the cutting cylinder 1, concentrically with an axis of rotation 73 and cooperates with a primary coil 76 placed at a short distance from--approximately 1 mm--and also disposed fixedly on the lateral frame 4 concentrically with the axis of rotation 73, which in turn is connected with a primary electronic device 77. This primary electronic device 77 can be housed at an arbitrary distance, for example also on the inside of the lateral frame 4. Such a contactless system for transmitting output is offered, for example, by MESA Systemtechnik GmbH of Konstanz.
In accordance with FIG. 7, in a fourth preferred embodiment of a drive for the lifting spindle 8, movable in the axial direction and supporting the stay bolts 34, 35, the lifting spindle 8 also terminates at its first end in the interior of the cutting cylinder 1 and is embodied as a toothed rack 78 on its first end facing the left axle journal 2. The toothed rack 78 meshes with a pinion gear 79 which, in turn, is frictionally and interlockingly connected with an electric gear motor 81 disposed fixed on the cylinder. As already described in connection with FIG. 6, transmission of the control pulses as well as the power current can take place either via generally known electrical collector ring systems, as well as by means of contactless output transmission as already described above. The gear motor 81 and the pinion gear 79 connected therewith are housed in a hollow chamber 82 of the cutting cylinder 1, which is accessible via the axle journal 2 that is screwed to the front face of the cutting cylinder 1, for example.
A second cutter bar 22 which, in accordance with FIGS. 8 and 9, in a fifth preferred embodiment consists of a cutter insertion bar 28 and a guide strip 24, fastened to it by screws 26, is run in the groove or channel 17 extending in the axial direction and is held in the groove or channel 17, open at one side, of the cutting cylinder 1 by means of the screws 43, compression springs 44 and sliding blocks 46 shown in detail in FIG. 3. Hoses 82, 83 are disposed on both sides of to the cutter insertion bar 28 and are connected for the introduction of compressed air by means of connecting hoses, not shown, in the axle journal 2 with a revolving connector 84, known from DE 39 43 119 C1, which is fastened on the axle journal 2 of the cutting cylinder 1. The revolving connector 84 has, for example, four compressed air connections, identified as a whole by 86, which are supplied with compressed air from a compressed air installation at a pressure of preferably 6 to 8 bar via valves, not shown. The second cutter bar 22 can be moved back and forth in the circumferential direction of the cutting cylinder, i.e. in both directions, by alternating charging of the hoses 82 or 83 with compressed air. In the course of this, the hose 82 is supported on a first lateral wall 87 of the groove or channel 17 and the hose 83 on a second lateral wall 88 located opposite the lateral wall 87. It is possible to continuously change the cutter bar 22 in the circumferential direction in accordance with production requirements. The same also applies correspondingly for the actuation of a first cutter bar 21 of the cutting cylinder 1.
In a sixth preferred embodiment it is also possible to replace one of the hoses 82 or 83, for example the hose 82, with springs 89 in accordance with FIG. 10, which are disposed in blind bores 90 along the first lateral wall 87 and which continuously keep the cutter bar 22 under prestress. The springs 89 can be embodied as cylindrical helical compression springs. By means of a metered charge of compressed air of the hose 83 it is possible to continuously adjust the second cutter bar 22 in the circumferential direction in response to the product requirements. The same also applies correspondingly to the actuation of a first cutter bar 21 of the cutting cylinder 1. In FIGS. 8 to 10, the cutter bar 22 is in a center position, i.e. for cutting of cut pieces of different length having an average difference in length.
In a seventh preferred embodiment, as seen in FIGS. 11, 12 and 13, a cutter bar 22 is disposed in a groove or channel 17 with first and second lateral walls 87, 88 and a bottom 19 of a cutting cylinder 1. On its side facing the first lateral wall 87 of the groove or channel 17, the cutter bar 22 has a first lateral face 91 rising one-sidedly in a wedge shape at a wedge angle β over its entire length 1 in FIGS. 11 and 12. A strip 92, embodied wedge-shaped on one side and having a face 93, is disposed between the lateral wall 87 of the groove 17 and the wedge-shaped first lateral face 91, and also rises at an angle β with respect to the horizontal center line 42. The face 93 of the strip 92 faces the wedge-shaped rising side 91 of the cutter bar 22 in a complementary manner, so that both angles β result in a complementary straight line which corresponds to a back 94 of the strip 92 resting against the first lateral wall 87 of the groove or channel 17. On its side facing the bottom 19 of the groove 17, the cutter bar 22 has two pins 96, 97, which are in frictional and interlocking connection with two grooves 98, 99 extending in the circumferential direction of the cutting cylinder 1 in the bottom 19 of the groove 17 and terminating in round ends. The second lateral wall 88 of the groove 17 has two blind bores 90 in which springs 89 are disposed which keep the cutter bar 22 continuously under prestress. The springs 89 can be designed as cylindrical helical pressure springs. The wedge strip 92 is provided with respective links 101, 102 at is end faces, which are respectively frictionally connected via a two-armed lever 103, 104 and a further link 106, 107 with actuator means 108, 109 fixed on the cylinder 1. Each two-armed lever 103, 104 is supported approximately in the center by a bearing 111, 112 fixed on the cylinder 1. The actuator means 108, 109 are used for shifting the wedge-shaped strip 92 in the axial direction, so that the cutter bar 22 performs a motion in the circumferential direction of the cutting cylinder 1. The pins 96, 97 and the grooves 98, 99 assure a parallel guidance of the cutter bar 22. It is also possible to dispose the pins 96, 97 fixed on the cylinder and the grooves 98, 99 in the cutter bar 22. The actuator means 108, 109 can be a known electromagnet, a linear motor 69, a gear motor 81 with a pinion gear 79 engaging a toothed rack 78, a work cylinder 58 or a piezoelectric force transducer. The last mentioned piezoelectric force transducers are described in Dubbel, "Taschenbuch fur den Maschinenbau" Mechanical Engineering Handbook!, Volume 17, published by Springer, Berlin, Heidelberg, New York, London, Paris, under Index No. V14, Item 1.5.3 and Index No. W12, Item 2.5.1. The force transducer is manufactured in "sandwich construction" and has, for example, three metal plates disposed at a distance from each other and extending parallel with each other, between which the piezoelectric force generators are located. If now the force generators are charged with a d.c. voltage via the metal plates, wherein the metal plate disposed in the center between the force generators must always have a different polarity than the two metal plates resting from the outside against the force generators, the thickness or distance between the metal plates is changed either positively or negatively, depending on the above mentioned polarity. What was just said in connection with the displacement of the cutter bar 22 also applies to the displacement of the second cutter bar 21 disposed on the circumference of the cutting cylinder 1.
As shown in FIGS. 14 to 16, in an eighth preferred embodiment of the device, a guide strip 24 of a cutter bar 22 is disposed in a groove or channel 17 extending in an axial direction. To cause a movement of the cutter bar 22 in the circumferential direction, the side of the cutter bar 22 facing the bottom 19 of the groove or channel 17 has pins 96, 97 of the same material, which frictionally and interconnectedly engage grooves 113 and 114 with round ends extending in the bottom 19 at an angle α in respect to a center line 42 of the cutting cylinder 1.
Actuation of the cutter bar 22 in an amount "a" in the direction of the angle α extending in respect to the center line 42 of the cutting cylinder 1, so that maximally a displacement "c" of the cutter bar 22 in the circumferential direction of the cutting cylinder 11 will be achieved, and takes place by actuation means 116 fixed on the cylinder. Springs 118, preferably leaf springs, are disposed, frictionally connected on one side, between a first lateral wall 87 of the groove 17 and a long-axially extending side 117 of the cutter insertion bar 28 which are connected, for example by grooved dowel pins, with the first lateral wall 87 of the groove 17. Because of this, the cutter bar 22 is under continuous prestress. The actuator means 116 can comprise a known electromagnet, a linear motor 69, a gear motor 81 with a pinion gear 79 engaging a toothed rack 78, a work cylinder 58 or a previously described piezoelectric force transducer, and it is fixed on the cylinder via a bearing 119 and frictionally connected with the underside of the guide strip 24 via a bearing 121. Second actuator means 116, 113, 119 can be disposed on the opposite end face of the cutter bar 22. As already described, energy transfer can take place, in the case of compressed air, by means of revolving connectors 86, or for electrical energy by means of a known collector ring system or by means of contactless output transmitting systems 74, 76, 77. This applies correspondingly also to the actuation of a second cutter bar 21 disposed on the circumference of the cutting cylinder 1.
As represented in FIGS. 17 to 19, in a ninth preferred embodiment of the device in accordance with the present invention the guide strip 24 of a cutter bar 22 is disposed in an axially extending groove or channel 17. To obtain a movement of the cutter bar 22 in the circumferential direction, the side of the cutter bar 22 facing the bottom 19 of the groove 17 has two grooves 122, 123 with round ends, which are frictionally and interlockingly engaged by pins 125, 126 fixed on the cylinder. The grooves 122, 123 extend at an angle α in respect to a center line 42 of the cutting cylinder 1.
Actuation of the cutter bar 22 in an amount "a" in the direction of the angle α extending in respect to the center line 42 of the cutting cylinder 1, so that maximally a displacement "c" of the cutter bar 22 in the circumferential direction of the cutting cylinder 11 will be achieved, and takes place by actuation means 116 fixed on the cylinder. Analogous to the representation in FIGS. 14 and 15, springs 118, preferably leaf springs, are provided to keep the cutter bar 22 prestressed. It is possible to use the same actuator means 116 as in the eighth preferred embodiment in FIGS. 14 to 16 with an arrangement via bearings 119, 121. It is also possible to frictionally connect the actuator means 116 of FIG. 18 and FIG. 19 via a two-armed lever 127 disposed at the end face of the cutting cylinder 1 with the cutter bar 22 or the associated guide strip 24. The two-armed lever 127 is held approximately in the center by a bearing 128 fixed on the cutting cylinder and has respective links 129, 130 at its ends. Second actuator means 116, 121, 130, 128, 129 can be disposed on the opposite end of the cutter bar 22. Energy transfer can also take place as already described. This applies correspondingly also to the actuation of a second cutter bar 21 disposed on the circumference of the cutting cylinder 1.
It should be expressly noted that the principle of "an angled groove 39, 40; 113, 114; or 122, 123 in connection with a pin 65, 67; 66, 68; 125, 126 engaging the groove 39, 40; 113, 114; or 122, 123" for displacing the cutter bars 21, 22 in the direction of the circumference of the cutting cylinder 1 is based on the principle of the "inclined plane". In the process, depending on the actuation direction of the cutter bars 21, 22, respectively one portion of the circumference of a pin 65, 67; 66, 68; 125, 126 is supported on a first or inner "angled" guide face or on a second or outer "angled" guide face of the groove 39, 40; 113, 114; or 122, 123:
1a) The groove 39, 40 in the guide strip 24 cooperates with a pin 65, 67 movable in an axis-parallel direction (first ends of the stay bolts 34, 35)--FIG. 4--,
1b) The groove 39, 40 in the guide strip 23 cooperates with a pin 66, 68 movable in an axis-parallel direction (second ends of the stay bolts (34, 35)--FIG. 4--,
Looking in the direction of viewing of the top view of the cutting cylinder 1 in FIG. 1, the grooves 39, 40 of the guide strip 23 extend congruently with the grooves 39, 40 in the guide strip 24, since a movement of the stay bolts 34, 35 in the axial direction 42 causes a movement of the cutter bars 21, 22 toward each other.
2) A groove 113, 114, fixed on the cylinder, is respectively located in the bottom 18, 19 of the cylinder trough 16, 17 and cooperates with pins 96, 97, respectively disposed on the cutter bar 21, 22 or preferably the guide strip 23, 24--FIG. 14--.
Here, too, the grooves 113, 114 run in the same direction as described under Item 1b).
3) A groove 122, 123 respectively located in the cutter bar 21, 22 or preferably the guide strip 23, 24 cooperates with respectively two pins 125, 126, fixed on the cylinder and disposed on the bottom 18, 19 of the cylinder trough 16, 17--FIG. 17--.
Here, too, the grooves 122, 123 run in the same direction as described under Item 1b).
4. By means of an axis-parallel movement of a strip 92 with an "inclined plane" 93 against a side of the cutter bar 21, 22 embodied in a wedge-shape, the cutter bars 21, 22 are moved toward or away from each other in the circumferential direction of the cutting bar cylinder 1--FIG. 11--.
Looking in the direction of viewing of the top view in accordance with FIG. 11, the wedge-shaped strip 92 disposed in an axis-parallel direction in the cylinder trough 16, 17 extends congruently above a similar strip 92 in a cylinder trough 16.
While preferred embodiments of a device for adjusting a cutting stick for a cutting cylinder of a rotary press in accordance with the present invention have been set forth fully and completely hereinabove, it will be apparent to one of skill in the art that a number of changes in, for example, the overall size of the cylinder, the length of the cutting stick, the type of cutting blades used, and the like could be made without departing from the true spirit and scope of the present invention which is accordingly to be limited only by the following claims. | Cutting bars positioned on the peripheral surface of a cutting cylinder are shiftable circumferentially toward or away from each other to vary the lengths of signatures being produced when the folding apparatus is switched between collection and no collection production. The cutting bars are shiftable circumferentially in grooves provided on the surface of the cutting cylinder. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This patent application claims the benefit under 35 U.S.C. §119 of U.S. Provisional Patent Application No. 61/110,882, filed on Nov. 3, 2008, entitled “Vehicle Destabilization Devices and Methods for Arresting Forward Motion.” That application is incorporated herein in its entirety by reference.
TECHNICAL FIELD
[0002] The present disclosure relates generally to systems and methods for affecting the forward motion of a land vehicle. In particular, the present disclosure relates to systems and methods for destabilizing a moving land vehicle and causing the vehicle to overturn or deflect so as to affect the forward motion of the vehicle. The present disclosure also relates to systems and methods for damaging the chassis of a moving vehicle so as to affect the ability of the vehicle to continue moving.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1A is a schematic side view illustrating a stowed configuration of a vehicle destabilizing device in accordance with several embodiments of the present disclosure.
[0004] FIG. 1B is a schematic front view illustrating the stowed configuration of the vehicle destabilizing device shown in FIG. 1A .
[0005] FIG. 2 is a schematic side view illustrating a system for destabilizing a vehicle in accordance with several embodiments of the present disclosure.
[0006] FIG. 3A is a schematic side view illustrating a deployed configuration of a vehicle destabilizing device in accordance with a first embodiment of the present disclosure.
[0007] FIG. 3B is a schematic front view illustrating the deployed configuration of the vehicle destabilizing device shown in FIG. 3A .
[0008] FIG. 4A is a schematic side view illustrating a deployed configuration of a vehicle destabilizing device in accordance with a second embodiment of the present disclosure.
[0009] FIG. 4B is a schematic front view illustrating the deployed configuration of the vehicle destabilizing device shown in FIG. 4A .
[0010] FIG. 5A is a schematic side view illustrating a deployed configuration of a vehicle destabilizing device in accordance with a third embodiment of the present disclosure.
[0011] FIG. 5B is a schematic front view illustrating the deployed configuration of the vehicle destabilizing device shown in FIG. 5A .
[0012] FIG. 6 is a perspective view illustrating a stowed configuration of a vehicle destabilizing device in accordance with a fourth embodiment of the present disclosure.
[0013] FIG. 7A is a top plan view illustrating the stowed configuration of the vehicle destabilizing device shown in FIG. 6 .
[0014] FIG. 7B is a side view illustrating the stowed configuration of the vehicle destabilizing device shown in FIG. 6 .
[0015] FIG. 8 is a perspective view illustrating a deployed configuration of the vehicle destabilizing device shown in FIG. 6 .
[0016] FIG. 9A is a side view illustrating the deployed configuration of the vehicle destabilizing device shown in FIG. 6 .
[0017] FIG. 9B is a back view illustrating the deployed configuration of the vehicle destabilizing device shown in FIG. 6 .
[0018] FIG. 10 is a perspective view illustrating an example of a deployment limiter for the vehicle destabilizing device shown in FIG. 6 .
[0019] FIG. 11A is a perspective view illustrating a detail of the vehicle destabilizing device shown in FIG. 6 .
[0020] FIG. 10B is a perspective view illustrating an example of an air spring for the vehicle destabilizing device shown in FIG. 6 .
[0021] FIG. 11C is a perspective view illustrating an example of a cold gas supply for the vehicle destabilizing device shown in FIG. 6 .
DETAILED DESCRIPTION
Overview
[0022] The following describes embodiments of vehicle destabilizing devices and methods of destabilizing vehicles in accordance with the present disclosure. Embodiments in accordance with the present disclosure are set forth in the following text to provide a thorough understanding and enabling description of a number of particular embodiments. Numerous specific details of various embodiments are described below with reference to destabilization devices for vehicles having wheels engaging a paved surface, but embodiments can be used with other types of terrain (e.g., dirt, gravel, and other non-paved surfaces). In some instances, well-known structures or operations are not shown, or are not described in detail to avoid obscuring aspects of the inventive subject matter associated with the accompanying disclosure. A person skilled in the art will understand, however, that the invention may have additional embodiments, or that the invention may be practiced without one or more of the specific details of the embodiments as shown and described.
[0023] According to several embodiments of the present disclosure, a device for destabilizing a moving vehicle causes the vehicle to overturn or deflect so as to affect its forward motion. Certain embodiments according to the present disclosure are directed to overturning, deflecting and/or damaging forward moving vehicles weighing up to 75,000 pounds and moving up to 75 miles per hour.
[0024] Certain embodiments of a system for affecting the forward movement of a vehicle may include two actuators by which first and second wheels on the same side of the vehicle are lifted. Certain other embodiments according to the present disclosure may include a single actuator for engaging only one of the wheels on one side of the vehicle. In still other embodiments, a single actuator can be configured to lift all of the wheels on one side of the vehicle. In yet other embodiments more than two actuators can be used, e.g., on target vehicles having more than two axles.
[0025] In certain embodiments, a system for affecting the forward movement of a vehicle on a surface may lift the wheels and/or chassis of a targeted moving vehicle to destabilize, deflect and/or overturn the vehicle as it travels along a path. An aspect of a system for affecting the forward movement of a vehicle includes a housing that has been installed or otherwise placed in the ground or on a road surface in the path of a targeted vehicle. As the vehicle is driven over the housing, a lifting force is applied to one side of the vehicle, one wheel of the vehicle, a plurality of wheels on one side of the vehicle, the chassis on one side of the vehicle, etc. The lifting force destabilizes the vehicle by shifting the vehicle's center of gravity and thereby causes the vehicle to tip-over and/or deflect the forward motion of the vehicle.
[0026] Another aspect of certain embodiments of a system for affecting the forward movement of a vehicle may include being selectively armed and/or disarmed. When disarmed or safe, the system is placed into a “sleep” or “deactivated” mode in which vehicles may drive over the housing without consequence, much like a conventional speed bump. When the system is armed, however, the system will destabilize, deflect and/or overturn the next vehicle that drives across the housing. As hereinafter described, the system can be selectively armed and disarmed remotely via wired or wireless communication from a vehicle sensor and/or an operator controlled device.
[0027] Still another aspect of certain embodiments of a system for affecting the forward movement of a vehicle may include one or more actuators, which may include pneumatic actuators, hydraulic actuators, energetic actuators, and/or any suitably actuator that can be positioned between the housing and a ramp. When the system is armed and a target vehicle is detected, one or more actuators are actuated to rapidly lift the ramp on one side of the vehicle. Accordingly, a center of gravity of the vehicle is rapidly shifted as one side of the vehicle climbs the ramp. This introduces a vehicle tipping moment that can destabilize, deflect, overturn and/or otherwise affect the forward movement of the vehicle.
[0028] In some embodiments, an apparatus may shift a center of gravity of a moving vehicle to affect forward movement of the vehicle on a surface. The vehicle includes a wheel and a chassis. An aspect of such an apparatus may include a housing configured to be positioned in a path of the vehicle, a destabilizing member that is deployed from the housing, and a lifting device configured to lift the destabilizing member with respect to the housing. The destabilizing member is configured to lift one side of the vehicle.
[0029] In some other embodiments, a system may provide selective, remotely deployed destabilization of a moving vehicle. An aspect of such a system may include a housing configured to rest on a surface, a structural member configured to contiguously engage the moving vehicle, a lifting device configured to lift the structural member with respect to the housing, a safe/arm device, and a remote deployment device configured to actuate the lifting device to lift the structural member with respect to the housing. The safe/arm device has (a) a safe arrangement configured to prevent the lifting device from lifting the structural member with respect to the housing; and (b) an armed arrangement configured to permit the lifting device to lift the structural member with respect to the housing.
[0030] In still other embodiments, a method may affect forward movement of a vehicle on a surface. The vehicle includes a wheel. An aspect of such a method may include raising a ramp to an inclined arrangement with respect to a housing, locking the ramp in the inclined arrangement with respect to the housing, and shifting a center of gravity of the vehicle. Shifting the center of gravity of the vehicle includes (a) launching the wheel of the vehicle up the ramp locked in the inclined arrangement with respect to the housing; and (b) lifting one side of the vehicle. The one side of the vehicle has the wheel.
Apparatuses, Systems and Methods for Affecting Forward Motion of a Vehicle
[0031] FIGS. 1A and 1B are schematic side and front views, respectively, illustrating a first or stowed configuration of a vehicle destabilizing device 10 in accordance with several embodiments of the present disclosure. In the stowed configuration shown in FIGS. 1A and 1B , the device 10 can be packaged in a housing 20 . The housing 20 , which can possibly be reused, repackaged, or be recharged, is positioned in the path of an oncoming target vehicle V.
[0032] In the embodiment shown in FIGS. 1A and 1B , the housing 20 is configured as a road protuberance that at least partially protrudes above a road surface R. Such protuberances are typically referred to as a “speed bump” (also referred to as a “speed hump,” “road hump” or “sleeping policeman”). In other embodiments, the housing 20 may be laid on top of the road surface R. In still other embodiments, the housing 20 may be configured to be installed in a cut-away so as to be flush with the road surface R. In any event, the housing 20 may be configured such that its capability for vehicle destabilization is concealed from a driver of an oncoming target vehicle.
[0033] In the embodiment shown in FIG. 1 , the device 10 is deployed under the vehicle V. In certain embodiments, the device 10 can be permanently coupled in or on the road surface R in a regular path way of traffic, or the device can be deployed from the side of the road surface R.
[0034] FIG. 2 is a schematic side view illustrating a system, including the vehicle destabilizing device 10 , for arresting the forward motion of the vehicle V in accordance with several embodiments of the present disclosure. A sensor 50 is shown disposed in front of the device 10 , e.g., between the oncoming vehicle V and the device 10 .
[0035] The sensor 50 can be used to determine the presence of the vehicle V. For example, the sensor 50 can determine the presence of one or more characteristics of a vehicle including mass, heat, sound, electromagnetic field, vibration, motion, or another suitable property. The device 10 can be remotely armed and the sensor 50 can detect the proximity of an oncoming vehicle to initiate the deployment sequence.
[0036] According to other embodiments of the present disclosure, individual sensors can be disposed on or inside the housing 20 . For example, a proximity sensor can send an electrical signal to a pyrotechnical actuator, or another suitable sensor can signal a corresponding suitable actuator.
[0037] In the embodiment shown in FIG. 2 , at least one upsetting bump 70 , e.g., a speed bump or a speed dot can be positioned in front of the sensor 50 . The upsetting bumps 70 , three are shown in FIG. 2 , can be placed prior to the device 10 to aid in disrupting the forward motion of the vehicle V, e.g., by upsetting the vehicle V as it approaches the destabilizing device 10 . In other embodiments, the upsetting bump(s) 70 can be omitted.
[0038] FIGS. 3A and 3B are schematic side and front views, respectively, illustrating a second or deployed configuration of a vehicle destabilizing device 100 in accordance with a first embodiment of the present disclosure. The vehicle destabilizing device 100 includes a lift device 130 and a ramp 140 .
[0039] In the embodiment shown in FIGS. 3A and 3B , a lift device 130 raises a trailing end 140 a of the ramp 140 , which acts on one wheel W to create lift on one side of the vehicle V. The lift device 130 can include a piston actuator, an inflatable actuator, a hydraulic actuator, a pneumatic actuator, an energetic actuator (e.g., a pyrotechnical device), or any actuator suitable for raising the ramp 140 up from the road surface R. The ramp 140 can include any suitable structural member and can have a leading end 140 b pivotally coupled to the housing 20 . Alternatively, the leading end 140 b can be freely disposed relative to the housing 20 .
[0040] The device 100 is positioned on one side of the road surface R to lift the wheel W on one side of the vehicle V. Lifting one side of a vehicle in motion deflects and/or destabilizes the center of gravity of the moving vehicle, thereby causing the vehicle's forward momentum to be deflected and causing the vehicle to tip over or overturn. In certain embodiments, two or more actuators can lift the trailing ends of corresponding ramps so as to lift individual wheels on the same side of a vehicle.
[0041] In accordance with one embodiment of the present disclosure, the lift device 130 can include a pneumatically actuated air bag. The air bag expands in approximately 30 milliseconds and exerts up to approximately 100,000 pounds of force in raising the trailing end 140 b approximately 30 inches above the road surface R. Such an arrangement can overturn and/or deflect the forward motion of a vehicle weighing up to approximately 30 tons that is moving up to approximately 50 to 60 miles-per-hour.
[0042] FIGS. 4A and 4B are schematic side and front views, respectively, illustrating the second or deployed configuration of a vehicle destabilizing device 200 in accordance with a second embodiment of the present disclosure. The vehicle destabilizing device 200 includes one or more lift devices 230 (individual lift devices 230 a and 230 b are shown in FIG. 4A ) and corresponding lift surfaces 240 (individual lift surfaces 240 a and 240 b are shown in FIG. 4A ).
[0043] As compared to the vehicle destabilizing device 100 shown in FIGS. 3A and 3B , the lift surfaces 240 of the vehicle destabilizing device 200 are not pivoted. Instead, the lift devices 230 elevate the lift surfaces 240 out of the housing 20 . Otherwise, the lift devices 230 and lift surfaces 240 are generally similar to the lift device 130 and the ramp 140 , respectively, of the vehicle destabilizing device 100 .
[0044] FIGS. 5A and 5B are schematic side and front views, respectively, illustrating the second or deployed configuration of a vehicle destabilizing device 300 in accordance with a third embodiment of the present disclosure. The vehicle destabilizing device 300 includes a lift device 330 and a ramp 340 .
[0045] In the embodiment shown in FIGS. 5A and 5B , a lift device 330 raises a leading end 340 b of the ramp 340 , which engages the chassis C of a vehicle V after at least one wheel W has passed over the vehicle destabilizing device 300 .
[0046] Lift on one side of the vehicle V is created by the forward momentum of the vehicle V in a manner similar to that used during an Olympic pole vault. In the embodiment shown in FIGS. 5A and 5B , the trailing end 340 a of the ramp 340 is pivotally coupled to the housing 20 . Alternatively, the trailing end 340 b can be freely disposed relative to the housing 20 and ramp 340 can leverage off of the preceding wheel W of the vehicle V to create a fulcrum point. The leading end 340 b, having been raised by the lift device 330 , catches on or otherwise engages the underside, e.g., the chassis C, of the vehicle V. The vaulting action of the ramp 340 lifts one side of the vehicle V and deflects and/or destabilizes the center of gravity of the vehicle V. As with the vehicle destabilizing devices 100 and 200 , the vehicle destabilizing device 300 causes the vehicle's forward momentum to be deflected and/or causes the vehicle to tip over or overturn. Otherwise, the lift devices 330 and ramp 340 are generally similar to the lift device 130 and the ramp 140 , respectively, of the vehicle destabilizing device 100 .
[0047] FIG. 6 , 7 A and 7 B illustrate a stowed configuration of a vehicle destabilizing device 400 in accordance with a fourth embodiment of the present disclosure. The device includes a base or housing 410 that rests on or is otherwise fixed to a road surface R that is in the pathway of a target vehicle (not shown). The housing 410 includes a leading ramp 412 a and a trailing ramp 412 b with respect to a direction of vehicle travel indicated with the arrows A 1 and A 2 . The destabilizing device 400 in the stowed configuration as shown in FIG. 6 presents the appearance of a conventional speed bump or speed table to an approaching driver. Accordingly, a non-target vehicle approaching the stowed destabilizing device 400 , e.g., arrow A 1 , initially encounters the leading ramp 412 a, which leads onto a destabilizing member 420 , and then exits off the destabilizing device 400 , e.g., arrow A 2 , via the trailing ramp 412 b . Accordingly, the destabilizing member 420 may include a ramp that extends between a leading edge 420 a that is proximate to the leading ramp 412 a and a trailing edge 420 b that is proximate to the trailing ramp 412 b.
[0048] Referring additionally to FIG. 7A , the destabilizing member 420 may include a plurality of notches 422 (individual notches 422 a - d are shown in FIG. 7A ) in the leading edge 420 a. FIG. 7A also shows that the trailing ramp 412 a may include a plurality of notch pairs 414 (individual notch pairs 414 a - d are shown in FIG. 7A ). As will be further described below, the notches 422 and the notch pairs 414 receive various links in the deployed configuration of the destabilizing device 400 .
[0049] Referring to FIGS. 6 and 7B , the destabilizing member 420 may include a convex surface 424 . The surface 424 may provide a smooth transition from the leading ramp 412 a to the trailing ramp 412 b when a wheel of a non-target vehicle rolls over the destabilizing device 400 . In other embodiments, the surface 424 may be flat, a combination of convex and flat contours, or any contour that is suitable for leading from the leading ramp 412 a to the trailing ramp 412 b in the stowed configuration of the destabilizing device 400 . The surface 424 may be protected with a coating, e.g., paint or plastic, to protect the surface 424
[0050] A plurality of webs 430 (only one web 430 a is shown in FIGS. 6 and 7B ) may reinforce the contour of the surface 424 . Each web 430 may extend between a leading end 430 a that is proximate to the leading ramp 412 a and a trailing end 430 b that is proximate to the trailing ramp 412 b. The leading end 430 a may be pivotally disposed with respect to the housing 410 . For example, one or more pivot pins 432 may pivotally couple the webs 430 to the housing 410 as will be further described below. Individual webs 430 may also include a slot 434 extending from approximately a midpoint of the web 430 toward the trailing end 430 b. As will be further described below, each slot 434 receives a sliding pin 436 of a cooperating linkage. Each web 430 may also include one or more additional openings 438 (individual openings 438 ba - c are shown in FIG. 7B ) to reduce the weight without adversely affecting the strength of the web 430 .
[0051] FIGS. 8 , 9 A and 9 B illustrate a deployed configuration of the vehicle destabilizing device 400 . A lifting device 440 as further described below elevates the destabilizing member 420 to an inclined arrangement. As shown in FIGS. 8 and 9A , the pins 432 pivotally couple the webs 430 to flanges 416 , which are coupled to the housing 410 . The flanges 416 extend between and support the leading and trailing ramps 412 a and 412 b. Each flange 416 includes an “L” shaped lock slot 418 a and a cutout 418 b as will be further described below. The flanges 416 are received in the notches 422 in the inclined arrangement of the destabilizing member 420 .
[0052] A locking device 450 includes pairs of support links 452 (individual pairs of support links 452 a - d are shown in FIGS. 8 and 9B ) and pairs of lock links 454 (four pairs of lock links 454 are shown in FIGS. 8 and 9B ). Each pair of support links 452 is pivotally coupled to a corresponding flange 416 proximate to the trailing ramp 412 b and is slidingly coupled to a corresponding web 430 . The pairs of support links 452 are slidingly coupled to the webs 430 via the sliding pins 436 and the slots 434 . The pairs of support links 452 may be received in the notch pairs 414 of the trailing ramp 412 b when the pairs of support links 452 are in an erected arrangement.
[0053] Each pair of lock links 454 extends between a first end 454 a and a second end 454 b. The first ends 454 a are pivotally coupled by link pins 456 (only one link pin is indicated in FIG. 8 ) at approximately a midpoint along a corresponding pair of support links 452 . The second ends 454 b are slidingly coupled to a corresponding flange 416 via lock pins 458 (only one lock pin 458 is indicated in FIGS. 8 and 9A ), which extend through a correspond lock slots 418 a.
[0054] Referring now to FIGS. 6-9B , the destabilizing device 400 in the stowed configuration includes: (a) the destabilizing member 420 is pivotally supported with respect to the housing 410 by the pins 432 such that the trailing edge 420 b and the trailing end 430 b of the webs 430 are proximate to the trailing ramp 412 b; (b) the sliding pins 436 are in the slots 434 generally proximate to the midpoints of the webs 430 and the link pins 456 are received in the cutouts 418 a in the flanges 416 ; and (c) the lock pins 458 are near or at ends of the longer branches of the lock slots 418 a. The destabilizing device 400 in the deployed configuration includes: (a) the destabilizing member 420 inclined with respect to the housing 410 such that the trailing edge 420 b and the trailing end 430 b of the webs 430 are pivoted away from the trailing ramp 412 b ; (b) the sliding pins 436 have moved in the slots 434 to generally proximate to the trailing end 430 b of the webs 430 ; and (c) the lock pins 458 are in the shorter branches of the lock slots 418 a. Thus, the lifting device 440 raises the destabilizing member 420 from an approximately horizontal position to the inclined arrangement and also erects the pairs of support links 452 from an approximately horizontal position. This lifting and erecting may occur in less than 250 milliseconds, e.g., in approximately 100 milliseconds or less. As the pairs of support links 452 are erected, the pairs of lock links 454 draw the lock pins 458 along the length of the longer branches of the lock slots 418 a until the lock pins 458 drop into the shorter branches of the lock slots 418 a . Accordingly, dropping the lock pins 458 in the shorter branches of the lock slots 418 a secure the pairs of support links 452 in an erected arrangement, which secures the destabilizing member 420 in the inclined arrangement.
[0055] As best seen in FIGS. 9A and 9B , erecting the pairs of support links 452 may also cause pairs of spikes 460 (individual pairs of spikes 460 a - d are shown in FIG. 9B ) to project downward from the housing 410 . These pairs of spikes 460 may embed in the road surface R to avoid or prevent movement of the destabilizing device 400 with respect to the road surface R when a target vehicle engages the destabilizing device 400 in the deployed configuration.
[0056] Referring to FIG. 9B , corresponding flanges 416 , pairs of lock links 454 , pairs of support links 452 , and pairs of webs 430 are nested together in a group. Four of these groups are shown distributed between the housing 410 and the destabilizing member 420 ; however, it is envisioned that the destabilizing device 400 may include more or less groups that can be regularly, symmetrically, or asymmetrically distributed. Although pairs of lock links, support links, and webs are described for each group, it is also envisioned that each group could have single, triple, quadruple, etc. lock links, support links, and webs. Further, each group may include more than one flange. In the stowed configuration shown in FIGS. 6 , 7 A and 7 B, each group consists of a single flange 416 horizontally nested within a pair of lock links 454 , which are horizontally nested within a pair of support links 452 , which are horizontally nested within a pair of webs 430 . Nesting horizontally, or at least approximately horizontally, may reduce the overall height of the destabilizing device 400 in the stowed configuration.
[0057] Certain embodiments according to the present disclosure can control the deployment movement of the destabilizing device 400 , e.g., control the speed at which the destabilizing member 420 moves between the stowed and deployed configurations. For example, it may be desirable to slow the speed that the destabilizing member 420 moves as it is approaches the deployed configuration, thus reducing the momentum of the destabilizing member 420 and reducing a counter force for positioning the destabilizing device 400 with respect to the road surface R. Accordingly, it may be possible to reduce the number and/or size of stakes fixing the housing 410 to the road surface R. The shape, position, and/or angular orientation of the slots 434 in the webs 430 may control the deployment of the destabilizing device 400 . For example, the force required to erect the pairs of support links 452 may increase as the destabilizing member 420 approaches the inclined arrangement. This may be caused by varying the relative angle between the slots 434 and the arcuate paths of the sliding pins 436 as set by the length of the pairs of support links 452 . Additionally or alternatively, the width of the slot 434 may taper so as to increasing the relative friction between the slots 434 and the sliding pins 436 as the pairs of support links 452 approach the erected arrangement.
[0058] Certain other embodiments according to the present disclosure may have different devices and/or mechanisms for locking the destabilizing member 420 in the inclined arrangement or for controlling the movement of the destabilizing member 420 . For example, a telescopically nested group of posts may be pivotally coupled at opposite ends to the destabilizing member 420 and the housing 410 . The extent to which the group of posts can be telescopically expanded may of set, e.g., by spring biased locking members, to fix one post to a telescopically adjacent post. Friction members placed between telescopically adjacent posts can be deformed or cause the posts to be deformed for controlling the movement of the destabilizing member 420 .
[0059] FIG. 10 shows a strap 470 coupled to the destabilizing member 420 and the housing 410 . The strap 470 may limit a distance that the destabilizing member 420 can travel with respect to the housing 410 . Further, the elastic properties of the strap 470 can be selected to control the movement of the destabilizing member 420 at the limit of its travel with respect to the housing 410 . Additionally or alternatively, folds of the strap 470 can be sewn together with rip stitches to control the movement of the destabilizing member 420 with respect to the housing 410 . Varying the size of the folds and/or the force required to burst the rip stitches can vary the control along the travel of the destabilizing member 420 with respect to the housing 410 .
[0060] FIGS. 11A-11C illustrate details of the lifting device 440 for the vehicle destabilizing device 400 . The lifting device 440 shown in FIG. 11A and 11B includes a gas spring 442 coupled to a gas supply 446 . Referring additionally to FIG. 11C , the gas spring 442 can include a bladder 442 a fixed between a top plate 442 b and a bottom plate 442 c. One example of a suitable bladder 442 a is a triple convoluted bladder (part number YI-FT 960-34-761) manufactured by Enidine USA of Orchard Park, N.Y. The top plate 442 b may include a fixture 444 to contact or to be coupled with the destabilizing member 420 . The bottom plate 442 c may provide a fluid coupling between the inside of the bladder 442 a and the gas supply 446 . The gas supply 446 can include a cold gas supply, e.g., a pressurized air tank, coupled for fluid communication with the bottom plate 442 c via a conduit 448 a and a valve 448 b. The valve 448 b can include a normally closed, pyrotechnically opened valve for rapidly inflating the gas spring 442 . The bladder 442 a can also include a pressure relief valve (not shown) that may vent pressure from the bladder 442 a at such time as the lifting device 440 has completing deployment, e.g., the destabilizing member 420 is locked in the inclined arrangement by the locking device 450 .
[0061] Certain embodiments according to the present disclosure can lift the destabilizing member 420 with devices that use one or more bladders, bladders having different arrangements, shapes or sizes, and/or one or more gas supplies including different fluids or a gas generator. Additionally, pyrotechnical, hydraulic, electrical or mechanical devices can be used together with and/or in lieu of the lifting device 440 .
[0062] A method according to embodiments of the present disclosure for implementing a vehicle destabilizing device will now be described. A vehicle destabilizing device 100 , 200 , 300 or 400 can be positioned in a “decision zone” that can be positioned prior to a “stop zone” at a checkpoint, an entry gate, or any other location at which it is desirable to screen vehicle traffic. A vehicle approaching the location would typically slow to allow security personnel manning the location to have an opportunity to investigate the vehicle as it comes to a stop in the decision zone. A friendly vehicle is typically allowed to pass through the decision zone and bypass the stop zone. In the event that a vehicle does not halt for investigation in the decision zone, the security personnel can selectively arm the vehicle destabilizing device 100 , 200 , 300 or 400 such that prior to the vehicle rolling over the vehicle destabilizing device 100 , 200 , 300 or 400 , the sensor 50 will initiate deploying the vehicle destabilizing device 100 , 200 , 300 or 400 . As the target vehicle approaches the vehicle destabilizing devices 100 , or the target vehicle rolls over the vehicle destabilizing devices 200 or 300 , the lifting devices 130 , 230 or 330 are actuated such that the ramp 140 raises a wheel W, the lift surface 240 elevates a wheel W, or the ramp 340 vaults the chassis C. Similarly, as a target vehicle approaches the vehicle destabilizing device 400 , the lifting device 440 lifts and then the locking device 450 locks the destabilizing member 420 in the inclined arrangement for launching a wheel W. The inclined arrangement may include an angle of inclination with respect to the road surface R of between approximately 25 degrees and approximately 45 degrees, e.g., approximately 36.5 degrees. Upward motion acting on the chassis and/or one or more wheels on one side of the vehicle throws off the center of gravity of the vehicle, and the vehicle's forward motion is deflected and/or the vehicle is overturned. Moreover, the upward motion and/or subsequent return of a target vehicle to the road surface may be likely to damage the vehicle, e.g., bend or break the suspension, such that the vehicle is not serviceable to continue moving.
[0063] According to the present disclosure, several embodiments can include a vehicle destabilizing device that is packaged in the form of or housed in a portable speed-bump that is meant to be positioned in the path of traffic at a selective location or pathway of traffic. The speed bump can be used to slow down traffic and, unbeknownst to an operator of a target vehicle, the vehicle destabilizing device can arrest the forward movement of the target vehicle. The vehicle destabilizing device can include one or more sections, e.g., each four feet wide, position side-to-side for extending partially or entirely across a road surface of any width.
[0064] According to the present disclosure, several embodiments of a vehicle destabilizing device can be remotely armed in anticipation of a target vehicle. As the target vehicle approaches the vehicle destabilizing device, the lifting device can be deployed to initiate a series of destabilizing events. Else, the vehicle destabilizing device can also be remotely disarmed prior to a non-target vehicle reaching the vehicle destabilizing device. Once disarmed, the vehicle destabilizing device can serve back as a conventional speed-bump for merely slowing traffic.
[0065] According to the present disclosure, several embodiments of the vehicle destabilizing device can also be permanently or semi-permanently housed at or below the road surface on a drive way or pathway and remotely or directly activated in according to an aforementioned manner. Multiple vehicle destabilizing devices can be placed in sequence to overturn large vehicles.
[0066] Vehicle destabilizing devices in accordance with several embodiments of the present disclosure may be used in conjunction with preceding speed bumps or speed dots that aid in disrupting forward motion of a vehicle by upsetting the vehicle before it reaches the destabilizing device.
[0067] Additional embodiments according to the present disclosure can include batteries or solar cells to provide electrical power for the vehicle destabilizing device, indicators for the state of the battery charge and whether the vehicle destabilizing device has been armed, self diagnostics to evaluate the operability of the vehicle destabilizing device, and wireless or wired controllers for remotely arming of the vehicle destabilizing device from a suitable distance. Moreover, embodiments according to the present disclosure can include reinforcements to withstand heavy vehicles passing over the vehicle destabilizing device or can include features for protecting the vehicle destabilizing device from exposure to various environments such as water or sand.
[0068] From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications can be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited by the specific embodiments. | A vehicle destabilizing device that provides for the selective, remotely-deployed deflection and/or overturning of a targeted vehicle regardless of wheel or undercarriage configuration. The device is comprised of a combination of a remote arm/safe mechanism, a remote deployment switch, one or more lifting devices, a housing, and one or more structural members contiguously engaging the vehicle. The housing can be at least partially submerged in a road surface or protrude from the road surface so as to be driven over until deployed. A sensor can provide independent deployment once the device is armed. | 4 |
FIELD OF THE INVENTION
The invention relates to apparatus for binding an edge of a stack of sheets.
BACKGROUND OF THE INVENTION
A stack of paper sheets can be bound together at an edge by applying a thermally flowable adhesive to the edge and permitting it to penetrate slightly into the stack of pages and harden. For example, Minami U.S. Pat. No. 3,866,568 discloses a machine for binding a stack of sheets by causing the lower edge of the stack to travel past the upper surface of a drum rotating in a tank of heated adhesive so that adhesive is applied to the lower edge of the stack; immediately before the front edge of the stack reaches the drum, the drum is temporarily lowered out of adhesive-applying position, to keep excess adhesive from the front edge of the stack of sheets.
SUMMARY OF THE INVENTION
In one aspect our invention features adhesive sheet-binding apparatus with means to wipe adhesive off of the surface of a rotating drum immediately prior to the arrival of the leading portion of a stack of sheets, to prevent excess adhesive on the front edge of the stack. In preferred embodiments, the wiping means is means to move a doctor blade on the drum toward the drum for a short period of time immediately prior to the arrival of the leading portion of the stack of sheets; the means to move the doctor blade is a lever arm extending from the doctor blade to a position above the upper surface of the drum so that as the carriage with the stack of sheets travels over the drum, the lever is temporarily depressed, thereby moving the doctor blade toward the drum; both the end of the lever arm and a contacting member on the bottom surface of the carriage have inclined surfaces to cause downward movement of the end of the lever arm as the carriage travels over it; the contact member on the carriage can be adjusted laterally to adjust the timing of the wiping action of the doctor blade. In an alternative embodiment, the contact member on the carriage has a plurality of inclined surfaces for contacting the lever arm so that the lever arm moves up and down against the rotating drum surface to vary the thickness of adhesive along the lower edge of the stack of sheets.
In another aspect, our invention features a jog table located adjacent to the tank for the rotatable drum and underneath the sheet-carrying carriage when the carriage is in its position prior to travel past the drum. The jog table supports the lower edge of the stack of pages prior to application of the adhesive, and it is movably mounted to move downward prior to travel of the paper past the rotating drum. The jog table thus permits alignment of the edges of the sheets in the stack, and then moves out of position to reduce drag on the stack of sheets during their travel past the rotating drum. In preferred embodiments, the table moves forward and downward during initial travel of the carriage; rollers and cam surfaces are used to provide the forward and downward travel of the jog table; the jog table has cam surfaces at its bottom, and the frame of the binding apparatus supports the rollers; there are means to bias the jog table toward the drum, and mating protuberances on the upper surface of the jog table and on the lower surface of the carriage, to hold the jog table back prior to travel of the carriage, and to permit travel of the jog table with the carriage.
In another aspect, our invention features providing the traveling carriage with separators so that a plurality of stacks of sheets can be carried by the carriage past the rotating drum at one time. The separators are supported by the carriage and have lower ends that are spaced above the upper surface of the drum. In preferred embodiments, the separators have holes through them, and they are supported by horizontal rods that pass through the holes and are carried by the carriage; and the horizontal rods are supported by vertical members that are removably mounted on the carriage.
In another aspect, our invention features a bound stack of sheets with a cover that has a small folded-over portion at one end with the adhesive penetrating into the crease of the folded-over edge and the edges of the sheets and between the sheets. In use, the crease in the cover acts as a hinge instead of the adhesive, to maintain the integrity of the adhesive binding. In a preferred embodiment, there are two such covers, one on each face of the stack of sheets.
DESCRIPTION OF THE PREFERRED EMBODIMENT
We now turn to description of the structure and operation of the presently preferred embodiment of the invention after first briefly describing the drawings.
DRAWINGS
FIG. 1 is a perspective view, partially broken away, of apparatus for binding the edges of a stack of pages according to the invention.
FIG. 2 is a diagrammatic, vertical sectional view, taken at 2--2 of FIG. 1, of the FIG. 1 apparatus with some of its components in an initial position.
FIG. 3 is a view similar to FIG. 2 with some of its components in different positions.
FIG. 4 is a diagrammatic plan view, partially broken away, of adhesive-applying components of the FIG. 1 apparatus.
FIGS. 5 and 6 are vertical sectional views, taken at 5--5 of FIG. 1, of separator components of the FIG. 1 apparatus, both before and during use.
FIG. 7 is a top view of a covered and bound stack of sheets according to the invention.
FIG. 8 is an elevation of an alternative contact member for the FIG. 1 apparatus.
STRUCTURE
Referring to FIG. 1, there is shown binding apparatus 10 for applying a thermally flowable adhesive on the surface of rotatable drum 12 to the lower edges of stacks of sheets 14 as they travel in carriage 16 over the upper surface of drum 12. Carriage 16 is slidably mounted to travel along tracks 18 and 20 on frame 21, and has separators 22 mounted on it to separate stacks of sheets 14. Portion 24 of carriage 16 is movable toward portion 23 in a direction transverse to the axes of tracks 18, 20, to facilitate insertion of stacks of sheets 14, and has locking lever arm 26, to lock member 24 in place. Carriage 16 also has cover plate 28 on its front end to cover drum 12, which is heated in use, when carriage 16 is in its resting position.
Referring to FIGS. 2, 3, and 4, it is seen that drum 12 is mounted within heated adhesive tank 30 and extends slightly above the top of tank 30. Doctor blade 32 is pivotally mounted about shaft 34, and lever arm 36 is attached to one end of blade 32 (FIG. 4). Lever arm 36 has inclined ramp portion 38 and top portion 39 for contact with inclined portion 40 and lower surface 42 of contact member 46, adjustably attached to the bottom of portion 23 of carriage 16.
In FIG. 2, jog table 48 is shown adjacent to tank 30 and underneath carriage 16, in its initial position. Jog table 40 is supported by rollers 50, 52, mounted on frame 21, and is restrained from travel to the left by interference of protuberance 56, extending downward from the lower portion of carriage 16, with protuberance 58, on jog table 48.
In FIG. 3, carriage 16 is shown in a position immediately prior to arrival of the leading portion of lower edges 60 of stacks 14 at the upper surface of drum 12. Jog table 48 is in a position forward of and lower than that shown in FIG. 2, and the center, elevated portions of cam surfaces 62, 64 are resting on rollers 50, 52. Doctor blade 32 has been pivoted into position against the surface of drum 12, because lever 36 has been moved downward by contact member 46.
In FIG. 4, the construction and mounting of drum 12 in heated adhesive tank 30 are shown in detail. Drum 12 is solid aluminum and has an electrochemically-reduced aluminum oxide coating impregnated with fluorocarbon resins (provided by Sanford Process Corporation, Natick, MA under the trade designation "Sanford Hard Lube") to provide lubrication and wear resistance to both the outer and inner surfaces. Within bore 66 of drum 12 are mounted tightly-fitting, cylindrical heating cartridge 70 and thermostat cartridge 72. Springs 73, 75 are connected to cartridges 70, 72, and have hooked ends attached to fixed members of the machine to provide limited movement of cartridges 70, 72 with drum 12 against the forces of the springs. End 74 of drum 12 is connected to drive means (not shown).
Referring to FIG. 5, separators 22 are shown suspended on carriage 16 between clamping surfaces 76, 78. Separators 22 each have holes 80, through which rods 82 (one at the front and one at the back) pass. Rods 82 are supported by vertical members 84, which are removably mounted on portion 24 of carriage 16. Lower ends 85 of separators 22 are about 1/4" wide, and are positioned to travel above jog table 48 and the adhesive on rotating drum 12.
In FIG. 6 stacks of sheets 14 are shown compressed between separators 22 with member 24 of carriage 16 locked into position.
In FIG. 7 bound book 86 is shown. It is made of stack of sheets 14 and two covers 88, 90, all adhered together by hardened adhesive 92 at the edge with small folded-over portions 94 of covers 90.
OPERATION
In operation, carriage 16 is initially in the position shown in FIGS. 1 and 2, and portion 24 of carriage 16 is spaced from portion 23, as shown in FIG. 5. Stacks of sheets 14 are placed between separators 22 and clamping surfaces 76, 78, and lower edges 60 are supported by jogging table 48 and are thus aligned with each other. Front edge 49 of the stack is placed against transverse bar 47. Portion 24 is moved toward portion 23 and locked into position with the proper compression, as is shown in FIG. 6, by moving lever 26. Machine 10 is then activated, and carriage 16 travels along tracks 18, 20 so that lower edges 60 pass through, and pick up, the adhesive on the upper surface of rotatable drum 12. During this travel, drum 12 rotates in a clockwise manner (FIG. 2), opposing the travel of stacks of sheets 14. Carriage 16 travels at approximately 2 inches per minute, and the peripheral speed of drum 12 is 38% faster than the linear speed of carriage 16.
Referring to FIGS. 2 and 3, it is seen that when carriage 16 and jog table 48 are in the initial position (FIG. 2), table 48 is in a high position on top of rollers 50, 52, and is restrained from movement to the left, owing the interaction of protuberances 56, 58. In this position the upper surface of jog table 48 is 0.01" lower than the upper surface of drum 12. As carriage 16 moves to the left, inclined surface 40 of contact member 46 slides over inclined surface 38 of lever 36, thereby pushing lever 36 and doctor blade 32 down so that doctor blade 32 wipes adhesive off of the surface of drum 12. Also, as carriage 16 moves to the left, table 48 is moved forward by spring 59 at the same lateral velocity as carriage 16, and, owing to the shapes of cam surfaces 62, 64, jog table 48 also moves downward to the position shown in FIG. 3, while stacks of sheets 14 remain supported by carriage 16, thereby permitting travel of stacks of sheets 14 without friction from dragging on table 48. In this position, table 48 is about 1/16" below that shown in FIG. 2. As carriage 16 moves further to the left, lever arm 36 is no longer depressed by contact member 46, and doctor blade 32 raises, thereby permitting a controlled layer of adhesive on the upper surface of drum 12. A short time later, the leading portions of lower edges 60 of stacks of sheets 14 arrive at the upper surface of drum 12 in synchronization with the arrival of adhesive on drum 12, so that adhesive is not applied on front edge 49 of stacks of sheets 14. Carriage 16 continues moving to the left with lower edges 60 passing through adhesive on drum 12. The proper amount of adhesive is determined by the position of doctor blade 32 (which is adjustable by means not shown) and the speed of rotation of drum 12. The synchronization of the arrival of the adhesive on drum 12 with the arrival of the leading portion of lower edges 60 can be adjusted by moving contact member 46 to the right or left.
Drum 12 is maintained at the proper temperature by heating cartridge 70 and thermostat cartridge 72. Because drum 12 is solid aluminium and fits tightly around heating cartridge 70, it conducts heat very well. Because drum 12 has a lubricating surface, it slides over cartridges 70, 72, and because the surface is wear resistant, it slides past doctor blade 32 without harmful wear.
The folded-over construction of covers 90 permits a good binding to form with the adhesive in the crease of the covers, and also permits opening the covers easily and without deforming the adhesive, as is shown by the open cover on the right side of FIG. 7.
OTHER EMBODIMENTS
Other embodiments of the invention within the scope of the appended claims will become apparent to those of skill in the art. For example, contact member 46 can be replaced by contact member 96, shown in FIG. 8, so that there will be varying thickness of adhesive on drum 12 and along edges 60 of stacks of sheets 14. | A sheet stack is bound by applying adhesive with a drum from which adhesive is wiped just before the stack arrives to prevent excess adhesive on its front edge. Other features include a sheet-aligning jog table that moves out of position before the stack reaches the drum, the use of separators between a plurality of stacks that travel past the drum simultaneously, and a bound stack of sheets with a cover having a small, folded-over portion adjacent to the stack. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of priority based on Japanese Patent Application No. 2007-175542, filed on Jul. 3, 2007, disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of determining deterioration of pressurizing performance of a spot welding gun which sandwiches a work piece between a pair of electrode tips, that is, a movable side electrode tip and an opposition side electrode tip, and, while applying pressurizing force to the work piece, performs welding of the work piece.
2. Description of Related Art
In spot welding that uses a spot welding gun, welding is performed on a work piece while a specified pressurizing force is being applied to the work piece sandwiched between a pair of opposing electrode tips, that is, a movable side electrode tip and an opposition side electrode tip of the welding gun. The opposing separation of the pair of electrode tips is set to a predetermined amount by directly moving the movable side electrode tip relative to the fixed side electrode tip having been positioned at a prescribed position.
In general, the movable side electrode tip is controlled so as to be moved by the driving force of a servo motor in a direction of closing or opening the opposing separation between a pair of electrode tips at a specified speed to a predetermined position. The work piece is thereby subjected to a specified pressurizing force between the pair of electrode tips so that stable quality of welding is maintained.
When a spot welding system is to be set up anew (at the time of installation) or processing conditions for welding are to be altered, a parameter adjusting operation is performed in order to decide operating parameters of the mounted welding gun taking into account dynamical characteristics of the welding gun such as rigidity or friction. Next, a calibration adjusting operation is performed for calibration of a torque command provided to the servo motor that drives the spot welding gun and an actual pressing force produced at the distal end of the electrode tip by the torque command. These adjusting operations are preliminary operations to be performed before welding is carried out with the spot welding gun. Then, welding operation is performed repeatedly with the spot welding gun.
However, it is known that a driving mechanism comprising a servo motor or a reduction gear necessarily deteriorates due to secular change such as wear of a sliding mechanism. Thus, machine elements such as ball screws and bearings are subjected to secular change due to faults or wear after usage for a long term. If the secular change is large, for example, if the welding gun can no longer operate, even if the robot controller outputs torque command to the servo motor, the driving mechanism of the welding gun itself cannot be operated, so that deviation of the pulse encoder value from the torque command is produced, leading to output of an alarm from the robot controller. An operator can thus recognize the occurrence of an anomaly in the spot welding robot. On the other hand, if the magnitude of secular change is small, for example, when a slight wear or the like is produced in a sliding mechanism, the magnitude of torque used in actual pressing of the work piece may be decreased due to the increase of the wear in the mechanism, but does not give rise to output of an alarm. Thus, only the pressurizing force produced by the welding gun is decreased. In such a situation, it is necessary to perform diagnosis of the welding robot such as measurement of the pressurizing force in a predetermined timing, and to perform adjusting operation again for parameters and calibration in order to prevent the quality of welding from being lowered. However, since a pressure sensor used for measuring the pressurizing force is expensive, adequate number of sensors may not be provided, and then, welding may be performed without recognizing the change of pressurizing force, which may lead to degradation of welding quality.
Therefore, in order to avoid degradation of welding quality, a deterioration diagnostic method has been proposed for diagnosing deterioration of a drive mechanism for a spot welding gun which uses a servo motor as a driving source.
Various methods have been known for diagnosing deterioration of a drive mechanism, and an example of deterioration diagnosing method applied to a spot welding gun is disclosed in Japanese Patent Publication No. 2007-29994. In the invention disclosed in Japanese Patent publication No. 2007-29994, the pressurizing time from the start of driving the electrode (movable side electrode) until the work piece is sandwiched under a predetermined pressing force and the pressurizing position (pressurized position) of the electrode when the work piece is sandwiched under a predetermined pressing force, are obtained, and deterioration of the drive mechanism due to wear of the mechanism can be diagnosed by analyzing the obtained pressurizing time and pressurizing position using a method of statistical analysis.
However, with respect to obtaining pressurizing position as disclosed in Japanese Patent Publication No. 2007-29994, it is necessary that the wear of the distal end of the electrode tip has been accurately measured. Usually, the distal end of the electrode tip is deformed or worn for each welding, but the amount of wear of the distal end of the electrode tip is measured only once after several cycles of operation. Thus, the obtained pressurizing position of the electrode includes errors due to the wear of the distal end of the electrode tip, and the deterioration of the drive mechanism due to wear of the mechanism may not be diagnosed accurately. There is also a problem that, since the rise-up behavior of the pressurizing force is influenced by individual difference of the work pieces and teaching deviation, it is difficult to grasp the deterioration of the drive mechanism accurately.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of determining deterioration of pressurizing performance of a spot welding gun that permits the operational state of a spot welding gun having a movable side electrode tip to be detected more accurately without being influenced by the wear of electrode tips or individual difference of work pieces, and that can thereby diagnose the deterioration of a spot welding gun more accurately.
In order to attain the above object, in accordance with an aspect of the present invention, there is provided a method of determining deterioration of pressurizing performance of a spot welding gun which has a movable side electrode tip moved by driving force of a servo motor and a fixed side electrode tip in opposition to the movable side electrode tip and which carries out welding of a work piece under pressurized state between the movable side electrode tip and the fixed side electrode tip, the method comprising: obtaining reference data that reflect a dynamic state of the servo motor when the movable side electrode tip is moved in a straight line in a predetermined operational mode without bringing the movable side electrode tip into contact with the work piece in the case where the movable side electrode tip is operated normally and the work piece is pressurized with a specified pressurizing force; performing data processing on the reference data to extract a reference characteristic value to be referenced when determining deterioration of pressurizing performance of the spot welding gun; obtaining diagnostic data that reflect the dynamic state of the servo motor when the movable side electrode tip is moved in the operational mode without bringing the movable side electrode tip into contact with the work piece in the case where the operational state of the movable side electrode tip changes and the work piece is no longer pressurized with the same specified pressurizing force as in the case where the movable side electrode tip is operated normally; performing data processing on the diagnostic data to extract a diagnostic characteristic value to be provided in order to determine deterioration of pressurizing performance of the spot welding gun; and determining deterioration of pressurizing performance of the spot welding gun based on the reference characteristic value and the diagnostic characteristic value.
With the construction as described above, deterioration of pressurizing performance of a spot welding gun can be determined by extracting a reference characteristic value from reference data of a servo motor when the movable side electrode tip is operated normally and a work piece is pressurized at a predetermined pressurizing force, and by extracting a diagnostic characteristic value from diagnostic data of the servo motor when the operational state of the movable side electrode tip changes and the work piece is no longer pressurized at a predetermined pressurizing force, and by comparing the reference characteristic value with the diagnostic characteristic value. The reference data and the diagnostic data of a servo motor are data obtained without bringing the movable side electrode tip into contact with the work piece, and therefore, are not influenced by the wear of the electrode tip or individual difference of the work pieces, so that the operational state of the spot welding gun having the movable side electrode tip can be detected more precisely, and deterioration of the spot welding gun can be diagnosed more accurately.
In the method of determining deterioration of pressurizing performance of a spot welding gun as described above, it is also possible to take, as the operational mode, a stepwise velocity command mode in which the movable side electrode tip is moved in a continuous operation at stepwise different moving velocities, and to obtain the reference data and the diagnostic data at the different moving velocities, and to extract the reference characteristic value by data processing of individual reference data, or to extract the diagnostic characteristic value by data processing of individual diagnostic data. With such construction, reference data and diagnostic data can be efficiently obtained in a continuous operation of the movable side electrode tip, and deterioration can be diagnosed more accurately.
In the method of determining deterioration of pressurizing performance of a spot welding gun as described above, it is also possible to take, as the operational mode, an intermittent velocity command mode in which the movable side electrode tip is moved at different individual moving velocities, and to obtain the reference data and the diagnostic data at the different moving velocities, and to extract the reference characteristic value by data processing of individual reference data, or to extract the diagnostic characteristic value by data processing of individual diagnostic data. With such construction, reference data and diagnostic data can be obtained in a simple method, and deterioration can be diagnosed accurately.
In the method of determining deterioration of pressurizing performance of a spot welding gun as described above, it is also possible to take, as the reference data or the diagnostic data, data selected from the group consisting of an estimated torque value estimated based on the current value that is inputted to drive the servo motor and an actual moving velocity obtained from a pulse encoder of the servo motor, an error between the displacement command value given to the servo motor and detected position obtained from the servo motor, a torque command value gave to the servo motor, and a current command value gave to the servo motor. With such construction, the range of application of the method of determining deterioration of a spot welding gun can be expanded.
In the method of determining deterioration of pressurizing performance of a spot welding gun as described above, it is also possible to take, as the reference characteristic value or the diagnostic characteristic value, data selected from the group consisting of maximum value, minimum value, average value, deviation value that is a deviation from the average value, convergence value, convergence time for converging to the convergence value of the reference data or the diagnostic data measured when the moving velocity reaches a constant, and rate of change of said reference data or the diagnostic data. With such construction, the range of application of the method of determining deterioration of a spot welding gun can be expanded.
In the method of determining deterioration of pressurizing performance of a spot welding gun as described above, it is also possible to take, as the reference characteristic value or the diagnostic characteristic value, the reference data or diagnostic data measured at the start of the movement of the movable side electrode tip. By thus obtaining the diagnostic characteristic value at the start of the movement of the movable side electrode tip, the start condition of the movement of the movable side electrode tip, and the range of application of the method of determining the deterioration of a spot welding gun can be expanded.
In the method of determining the deterioration of pressurizing performance of a spot welding gun as described above, it is also possible to perform data processing on a plurality of the reference characteristic values and a plurality of the diagnostic characteristic values to determine maximum value, minimum value, average value, and deviation value, and to use data selected from the group consisting of the maximum value, the minimum value, the average value, and the deviation value as a secondary reference characteristic value and a secondary diagnostic characteristic value, respectively. By using the secondary reference characteristic value and secondary diagnostic characteristic value obtained from a plurality of reference characteristic values and a plurality of diagnostic characteristic values to diagnose deterioration of the spot welding gun, a dynamical state of the spot welding gun can be determined rationally, and deterioration can be diagnosed more accurately.
It is also possible to display the reference characteristic value or the diagnostic characteristic value on output means. By displaying the reference characteristic value or the diagnostic characteristic value, an operator can be made to recognize the state of the spot welding gun.
In the method of determining deterioration of pressurizing performance of a spot welding gun as described above, it is also possible to store the reference characteristic value and the diagnostic characteristic value, and by using statistical processing of the reference characteristic value and the diagnostic characteristic value recorded, to predict the diagnostic characteristic value for the next diagnosis. By thus predicting the diagnostic characteristic value for the next diagnosis, welding failure can be avoided in advance and reliability of welding quality can be improved.
In the method of determining deterioration of pressurizing performance of a spot welding gun as described above, it is also possible to calculate the difference value between the predicted diagnostic characteristic value for the next diagnosis and the stored diagnostic characteristic value, and to compare the difference value with a preset threshold to determine deterioration of the spot welding gun. By thus calculating the difference value between the predicted diagnostic characteristic value for the next diagnosis and the stored diagnostic characteristic value and comparing the difference value with a preset threshold, deterioration of pressurizing performance of the spot welding gun can be determined more accurately.
In the method of determining deterioration of pressurizing performance of a spot welding gun as described above, it is also possible to output an alarm for warning an anomaly of the spot welding gun to the outside if the pressurizing performance is determined to have deteriorated. By thus outputting an alarm for warning an anomaly of the spot welding gun to the outside, an operator who becomes aware of the alarm can stop the welding operation, and can prevent welding failure in advance.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features, and advantages of the present invention will become more apparent from the following description of preferred embodiments with reference to appended drawings, in which:
FIG. 1 is a front view of a robot system used in implementing a method of determining deterioration of pressurizing performance of a spot welding gun according to a first embodiment of the present invention;
FIG. 2 is a front view of a robot system used in implementing a method of determining deterioration of pressurizing performance of a spot welding gun according to a second embodiment of the present invention;
FIG. 3 is a block diagram of a robot controller shown in FIG. 1 and FIG. 2 ;
FIG. 4 is a flow chart explaining the method of determining deterioration of pressurizing performance of a spot welding gun;
FIG. 5 is a view explaining an example of movement pattern of a movable side electrode tip;
FIG. 6A is a view explaining the operation state of a servo motor at moving velocity of V 1 in another example of movement pattern of a movable side electrode tip;
FIG. 6B is a view explaining the operation state of a servo motor at moving velocity of V 2 in another example of movement pattern of a movable side electrode tip;
FIG. 6C is a view explaining the operation state of a servo motor at moving velocity of V 3 in another example of movement pattern of a movable side electrode tip;
FIG. 7 is a view explaining a converging time as an evaluation value and an amount of change relative to the converging time;
FIG. 8 is a view explaining the timing for obtaining reference characteristic value or diagnostic characteristic value when the movable side electrode tip starts movement;
FIG. 9 is a view explaining the method of calculating secondary evaluation value;
FIG. 10A is a view explaining an example of comparison of the present evaluation value with a reference value in a method of predicting the evaluation value of a spot welding gun;
FIG. 10B is a view explaining an example of comparison of the difference between previous and present evaluation values with a threshold in the same method of predicting the evaluation value of a spot welding gun;
FIG. 11A is a view explaining an example of predicting an evaluation value from N-th order regression line in another method of predicting the evaluation value of a spot welding gun;
FIG. 11B is a view explaining an example of a comparison of the evaluation value predicted from N-th order regression line with the presently recorded evaluation value in the another method of predicting the evaluation value of a spot welding gun;
FIG. 11C is a view explaining an example of comparison of the predicted evaluation value with the actual evaluation value actually recorded at the predicted time when the evaluation value for the next measurement is predicted from exponential approximation line of evaluation value in the another method of predicting the evaluation value of a spot welding gun.
DETAILED DESCRIPTION
The present invention will be described in detail with reference to drawings. FIG. 1 is a view of a robot system used in implementing a method of determining deterioration of pressurizing performance of a spot welding gun according to a first embodiment of the present invention. The robot system is not particularly limited, but is composed of a multi-joint type spot welding robot 1 having a spot welding gun 16 , and a robot controller 2 for controlling the spot welding robot. FIG. 2 is a view of a robot system used in implementing a method of determining deterioration of pressurizing performance of a spot welding gun according to a second embodiment of the present invention. Spot welding gun 16 shown in FIG. 2 is provided separately from robot 1 A, and is held on a distal end of a stem 15 on the floor. In FIG. 1 and FIG. 2 , common constituents are denoted by same reference numerals, and duplicate explanation thereof is omitted.
As shown in FIG. 1 , a spot welding robot 1 is a general 6-axes multi-joint type robot, comprising a base 3 fixed to the floor rotatably about a vertical first axis, an upper arm 4 connected to base 3 , a forearm 5 connected to upper arm 4 , a wrist element 6 rotatably connected to the distal end of forearm 5 , and a spot welding gun 16 mounted to the end of wrist element 6 . Upper arm 4 is attached to base 3 rotatably about a horizontal second axis. To the upper end of upper arm 4 , the proximal end of forearm 5 is connected rotatably about a horizontal third axis. To the distal end of forearm 5 , wrist element 6 is connected rotatably about a fourth axis parallel to the axis of forearm 5 . To the distal end of wrist element 6 , an unshown wrist element is connected rotatably about a fifth axis orthogonal to the axis of forearm 5 . To the unshown wrist element, spot welding gun 16 is mounted rotatably about a sixth axis orthogonal to the fifth axis.
Spot welding gun 16 has an unshown linkage section rotatably connected to the wrist element, a gun arm 7 formed in the shape of inverted “C” integrally with the linkage section, and a sandwiching servo motor 12 . Gun arm 7 has a fixed side electrode tip 14 a , and a movable side electrode tip 14 b which is opposed to fixed side electrode tip 14 a and can move freely to come into contact with or away from fixed side electrode tip 14 a . A pair of electrode tips 14 a , 14 b are bar-shaped and are disposed coaxially in the plate-thickness direction of a work piece 11 .
Fixed side electrode tip 14 a is adapted to have its position and attitude controlled by servo motor 12 driving various axes of robot 1 . Thus, when fixed side electrode tip 14 a is to be positioned to a taught position (position of spot welding point) in the plate-thickness direction of work piece 11 , fixed side electrode tip 14 a is driven by servo motor 12 that drives various axes of robot 1 . On the other hand, movable side electrode tip 14 b is driven by sandwiching servo motor 12 of spot welding gun 16 at a specified velocity to a predetermined position in a direction a pair of opposing electrode tips 14 a , 14 b.
Sandwiching servo motor 12 has an unshown power amplifier and an encoder mounted thereon. The current is amplified by the power amplifier and is supplied to servo motor 12 . It is also possible to use a feedback control to obtain an estimated torque from the current value of servo motor 12 via an external disturbance observer 48 (see FIG. 3 ). The encoder is mounted in order to detect the rotation angle of servo motor 12 about its axis. With feedback control, the detected rotation angle is fed back, and movable side electrode tip 14 b is positioned at a specified position so as to impart a predetermined pressurizing force to work piece 11 between a pair of electrode tips 14 a , 14 b . Although spot welding gun 1 , 1 A in the present embodiment and the second embodiment has no pressure sensor for detecting actual pressurizing force mounted thereon, it is also possible to provide a pressure sensor.
Robot controller 2 can drive one of the pair of electrode tips 14 a , 14 b , that is, movable side electrode tip 14 a in opposing direction by means of servo motor 12 so as to control the pressurizing force on work piece 11 sandwiched between the pair of electrode tips 14 a , 14 b , and composes a digital servo circuit comprising an unshown CPU, various memories, and an I/O interface to perform position control, velocity control, torque (current) control and the like.
Operating program, teaching data, and the like for spot welding robot 1 , 1 A are stored in the memories as storage means. Teaching data include the data of spot welding point that indicate the position and attitude of spot welding robot 1 , 1 A, and spot welding gun 16 when spot welding is to be performed on multiple points of work piece 11 . The position and attitude of spot welding robot. 1 , 1 A is not particularly limited, but in the present embodiment, spot welding gun 16 has a pair of electrode tips 14 a , 14 b arranged in a vertical direction.
FIG. 3 is a block diagram showing a part of the construction of the robot controller. Servo motor 12 provided in spot welding gun 15 is controlled in position control based on position information fed back from a pulse encoder, position command and position control gain 46 delivered from an operating command portion 22 via a common RAM 42 . Here, 1/s in the position feedback circuit means an integration operation, and s is a Laplace operator.
Servo motor 12 is controlled in torque control based on the estimated external torque disturbance estimated by an external disturbance observer 48 , a position command value delivered from operation command portion 22 via common RAM 42 , a torque command delivered from common RAM 42 , and position control gain 46 . The estimated external torque disturbance is a torque disturbance of servo motor 12 estimated from the motor control current and the actual motor speed using external torque disturbance observer 48 . In the case of a spot welding gun 16 , the external torque disturbance imposed on servo motor 12 corresponds to pressurizing force generated by pressing electrode tips 14 a , 14 b to each other and frictional force produced by the movement of movable side electrode tip 14 a . In the description that follows, the estimated external torque disturbance estimated by observer 48 is used as the state variable representing dynamical characteristics of servo motor 12 .
As shown in FIG. 1 and FIG. 2 , a teaching pendant 8 which permits information in robot controller 2 to be read out or operation and setting of robot controller 2 to be performed, and a peripheral equipment 9 which communicates via a communication interface with robot controller 2 are connected to robot controller 2 .
FIG. 4 is a flow chart showing a method of determining deterioration of pressurizing performance of a spot welding gun 16 . In FIG. 4 , an evaluation value means a reference value (reference characteristic value).
First, at step S 1 , at a diagnosing time which can be selected arbitrarily by an operator, movable side electrode tip 14 b is moved at a specified moving velocity pattern (operational mode) in closing or opening direction relative to fixed side electrode tip 14 a.
Here, as an example of operational pattern, movement pattern as shown in FIG. 5 and FIGS. 6A-C may be used. The movement pattern shown in FIG. 5 is a stepwise pattern in which movable side electrode tip 14 b is moved in a stepwise different moving velocity in one-time continuous operation, and closing or opening movement of movable side electrode tip 14 b is performed at moving velocities of V 1 , V 2 , V 3 . At different moving velocities of V 1 , V 2 , V 3 , estimated torques corresponding to reference data or diagnostic data are obtained. An evaluation value as a reference characteristic value or a diagnostic characteristic value can be extracted by data processing of the estimated torque.
On the other hand, the movement patterns shown in FIGS. 6A-C are intermittent velocity command patterns in which movable side electrode tip 14 b is moved at different individual moving velocities of V 1 , V 2 , V 3 , and closing or opening movement of movable side electrode tip 14 b is performed at individual moving velocities of V 1 , V 2 , V 3 . FIG. 6A shows the operational state of servo motor 12 at moving velocity of V 1 , FIG. 6B shows the operational state of servo motor 12 at moving velocity of V 2 , and FIG. 6C shows the operational state of servo motor 12 at moving velocity of V 3 , respectively.
In FIG. 5 and FIGS. 6A-C , the measurement interval for which the reference characteristic value or diagnostic characteristic value is obtained is taken to be the interval for which, after a velocity command is outputted from robot controller 2 to servo motor 12 , actual moving velocity of the servo motor is a constant velocity.
In FIG. 5 and FIGS. 6A-C , an estimated external torque disturbance is obtained as the reference data or diagnostic data reflecting the dynamical characteristics of servo motor 12 . However, it is also possible to obtain an error between the displacement command value given to servo motor 12 and the actual movement value obtained from the pulse encoder provided on servo motor 12 , the torque command value for servo motor 12 , the current command value for servo motor 12 , or the like.
Next, at step S 3 , an evaluation value is calculated, and at step S 4 , the evaluation value is recorded. With reference to the movement pattern shown in FIG. 5 , maximum value T max1 of the estimated external torque disturbance of servo motor 12 when the moving velocity command is a constant velocity V 1 is obtained as an evaluation value. Similarly, maximum values T max2 , T max3 of the estimated external torque disturbance of servo motor 12 for constant velocities V 2 , V 3 are obtained as evaluation values. Also, average value T avg1 of the estimated external torque disturbance of servo motor 12 when the moving velocity command is a constant velocity V 1 is obtained as an evaluation value. Similarly, average values T avg2 , T avg3 of the estimated external torque disturbance of servo motor 12 for constant velocities V 2 , V 3 are obtained as evaluation values. In addition, minimum value, deviation value, convergence value, converging time Δt, change of obtained data ΔT relative to converging time can be obtained as evaluation values. Calculated evaluation values are stored together with the date and time of the record in the memory of robot controller 2 such that an operator can use a teaching pendant 8 or the like to read the evaluation values freely.
As shown in FIG. 7 , converging time Δt can be calculated as the difference of time from the time when the moving velocity command reaches to a constant velocity V until the estimated external torque disturbance of servo motor 12 converges to a constant value. Change of obtained data ΔT relative to converging time Δt can be calculated from converging time Δt and the difference of the estimated external torque disturbance when the moving velocity command reaches to a constant velocity V and the convergence value.
FIG. 8 shows the timing for obtaining the reference characteristic value or the diagnostic characteristic value when the movable side electrode tip starts movement.
In FIG. 8 , after the velocity command is outputted from the robot controller to servo motor 12 , the external torque disturbance at the time of the start of movement of the movable side electrode tip can be obtained when the actual moving velocity of servo motor 12 reaches the value of 0 or higher. Although not shown, other values such as an error between the displacement command to servo motor 12 and the actual movement obtained from the pulse encoder provided in servo motor 12 , the torque command value to servo motor 12 , the current command value to servo motor 12 , and the like can be obtained. The obtained reference characteristic values or diagnostic characteristic values are used as evaluation values. It is to be understood that the characteristic value at the start of movement of the movable side electrode tip and the characteristic value when the moving velocity of the movable side electrode tip is in a constant velocity interval can be obtained simultaneously by implementing one movement pattern.
Next, at step S 5 , it is determined whether or not secondary evaluation values corresponding to secondary reference characteristic values or diagnostic characteristic values should be calculated. In case of YES, the secondary evaluation values are calculated at step S 6 , and the calculated secondary evaluation values are recorded at step S 7 . In case of NO, the processing proceeds to step S 8 .
Here, the secondary evaluation values are calculated as shown in FIG. 8 . Thus, based on the evaluation values calculated at step S 3 for various velocities, maximum value, minimum value, average value, and deviation are calculated. As an example, if in one measurement, for movement patterns of V 1 , V 2 , V 3 , the maximum values of estimated external torque disturbance for respective velocities T max1 , T max2 , T max3 are measured with the relation of T max1 <T max2 <T max3 , and if maximum value of the primary evaluation values is to be used as a secondary evaluation value, T max3 is the secondary evaluation value. If the average value of the primary evaluation value is to be used as a secondary evaluation value, the secondary evaluation value is (T max1 +T max2 +T max3 )/3. By calculating the secondary evaluation value in this way, measurement data can be evaluated comprehensively.
Next, at step S 8 , the evaluation value calculated from the estimated torque obtained when electrode tip 14 a moves normally and work piece 11 is pressurized by a specified pressurizing force, is compared with the diagnostic evaluation value calculated from the estimated torque obtained when the operational state of the movable side electrode tip changes and work piece 11 is not pressurized by a specified pressurizing force. At step S 9 , it is determined whether or not there is an anomaly, and if there is an anomaly, at step S 10 , notification is given to the outside informing an anomaly. Then, at step S 11 , an anomaly is displayed on the teaching pendant. Or, at step S 12 , an alarm signal is outputted.
Next, a method of predicting an evaluation value of a spot welding gun will be described with reference to FIGS. 10A , B and FIGS. 11A˜C . FIG. 10A is a view of a case in which the present evaluation value is compared with the reference value, and if the difference exceeds a threshold for an anomaly that can be set arbitrarily by an operator, it is determined that there is the anomaly. Specifically, when an evaluation value D 0 at time T 0 is compared with an evaluation value D n at time T n and a threshold E 1 for an anomaly has been set, if |D n −D 0 |>E 1 , it is determined that there is the anomaly (n is an integer, and means the number of the measurement).
FIG. 10B is a view of a case in which the present evaluation value is compared with the previous evaluation value, and if the difference exceeds a threshold for an anomaly that can be set arbitrarily by an operator, it is determined that there is an anomaly. Specifically, when an evaluation value D n−1 at time T n−1 is compared with an evaluation value D n at time T n and a threshold E 2 for an anomaly has been set, if |D n −D n−1 |>E 2 , it is determined that there is an anomaly (n is an integer, and means the number of the measurement).
FIG. 11A is a view of a case in which N-th order regression line of evaluation value for the time sequence is calculated from the present record of obtained evaluation values, and an evaluation value to be obtained in the next measurement is predicted, and compared with the reference value, and if it exceeds a threshold for an anomaly that can be set arbitrarily by an operator, it is determined that there is an anomaly. Specifically, as shown in the following Figure, from the trend of all the evaluation values from evaluation value D 0 at time T 0 to evaluation value D n at time T n , a linear regression line for the time sequence is calculated, and an evaluation value D n+1 at time T n+1 is determined from said regression line. Then, evaluation value D n+1 at time T n+1 is compared with evaluation value D n at time T n , and if a threshold E 3 for an anomaly has been set, and if |D n+1 −D 0 |>E 3 , it is determined that there is an anomaly (n is an integer, and means the number of the measurement).
FIG. 11B is a view of a case in which N-th order regression line of evaluation value for the time sequence is calculated from the present record of obtained evaluation values, and an evaluation value to be obtained in the next measurement is predicted, and compared with the presently recorded evaluation value, and if it exceeds a threshold for an anomaly that can be set arbitrarily by an operator, it is determined that there is an anomaly. Specifically, as shown in the following Figure, from the trend of all the evaluation values from evaluation value D 0 at time T 0 to evaluation value D n at time T n , a second-order regression line for the time sequence is calculated, and evaluation value D n+1 at time T n+1 is determined. Then, evaluation value D n+1 at time T n+1 from said regression line is compared with evaluation value D n at time T n , and if a threshold E 4 for an anomaly has been set, and if |D n+1 −D 0 |>E 4 , it is determined that there is an anomaly (n is an integer, and means the number of the measurement).
FIG. 11C is a view of a case in which an exponential approximation line for the time sequence is calculated from the present record of obtained evaluation values, and an evaluation value to be obtained in the next measurement is predicted, and compared with the actual evaluation value recorded at the predicted time, and if it exceeds a threshold for an anomaly that can be set arbitrarily by an operator, it is determined that there is an anomaly. Specifically, as shown in the following Figure, from the trend of all the evaluation values from evaluation value D 0 at time T 0 to evaluation value D n−1 at time T n−1 , an exponential approximation regression line for the time sequence is calculated, and the evaluation value at time T n predicted from said regression line is determined. Let an evaluation value actually recorded at time T n be D n ′, and if a threshold E 5 for an anomaly has been set, and if |D n −D n ′>E 5 , it is determined that there is an anomaly (n is an integer, and means the number of the measurement).
With the construction as described above, an operator can determine the timing of maintenance for a spot welding gun 16 , and thus can always use welding gun 16 in a suitable state of performance for production, and can contribute improvement of welding quality. Failure can be found early and preventive measures can be taken and sudden occurrence of trouble can be avoided.
The present invention is by no means limited to above-described embodiments, but can be implemented in various modifications without departing from the scope and spirit of the present invention. | A method of determining deterioration of pressurizing performance of a spot welding, the method having: obtaining reference data that reflect a dynamic state of a servo motor in a case where a movable side electrode tip is operated normally and a wok piece is pressurized by a specified pressurizing force; performing data processing on the reference data to extract a reference characteristic value; obtaining diagnostic data that reflect a dynamic state of the servo motor in a case where a operational state of the movable side electrode tip changes and the work piece is no longer pressurized by a specified pressurizing force; performing data processing on the diagnostic data to extract a diagnostic characteristic value; and determining deterioration of pressurizing performance of the spot welding gun based on the reference characteristic value and the diagnostic characteristic value. | 1 |
FIELD OF THE INVENTION
The present invention relates to a device for automatic removal of a milking means from an animal's udder, comprising a motor and a removal means rotatable by the motor in a first direction, the removal means being adapted to pull the milking means off the udder when the milking means is rotated by the motor in said first direction, and to admit movement of the milking means for its attachment on to the udder when the removal means is rotated in an opposite, second direction.
THE TECHNOLOGICAL STATE OF THE ART
Such a removal device, which is known from WO 93/00002, has great advantages, since it may be designed in very small dimensions and with a low weight. In the known removal device, the removal means comprises a cord drum with a cord adapted to be connected to the milking means. However, the known removal device has a drawback, since it has appeared that a mechanical resistance must be overcome each time the cord is to be pulled out from the cord drum in connection with attachment of the milking means onto the teats of an animal. The reason for this resistance is the motor, which is connected to the cord drum during the operation thereof. When pulling out the cord from the cord drum it may certainly be considered that the resistance of the removal device is not particularly strong, but in connection with repeated pull outs it has, after all, appeared that the resistance may be strenuous for the milker to overcome.
OBJECT OF THE INVENTION
The object of the present invention is to achieve an automatic removal device of the above described kind, which removes the above described disadvantage of the said known removal device.
SUMMARY OF THE INVENTION
This object is achieved by a device of the initially described kind, which is characterized by a coupling device adapted to keep the removal means operably connected to the motor when the removal means is rotated by means of the motor in said first direction and to keep the removal means disconnected from the motor when the removal means is rotated in said second direction. Thus, the removal means can be rotated in said second direction without resistance from the motor when the motor is not in operation, whereby the milker easily can move the milking means for its attachment onto the udder.
Advantageously, there is a means provided for influencing the coupling device such that the removal means is automatically connected to the motor when driven for rotation of the removal means in said first direction, said means comprising a source of positive or negative pressure adapted for pneumatic influence of the coupling device.
Preferably, the motor is pneumatically operable for rotation of the removal means in said first direction and is connectible to said source. The coupling device is in this connection adapted to operably connect the removal means to the motor, substantially simultaneously with the connection of the motor to said source. This can suitably be achieved by pneumatically connecting the coupling device and the motor to each other.
The motor may be a rotary motor, wherein the coupling device is interconnected between the motor and the removal means. In this case the coupling device suitably comprises a gear change device adapted to give the removal means a speed of rotation which is lower than that of the motor, whereby the motor can be designed compact, at the same time as a desired torque can be achieved.
Advantageously, said source is a vacuum source, which enables use of existing vacuum system in the milking stall.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be closer described with reference to the accompanying drawings, in which
FIG. 1A is a view of a longitudinal section through a removal device according to a preferred embodiment of the invention,
FIG. 1B shows a detail in enlargement of a coupling device in engaged state of the removal device according to FIG. 1A,
FIG. 1C shows the same detail as shown in FIG. 1B, but with the coupling device in unengaged state,
FIG. 2 is an exploded view illustrating details of a motor, a gear change device, a housing for the gear change device, and a removal means of the removal device according to FIG. 1A,
FIG. 3A shows a view of the interior of the housing illustrated in FIG. 2,
FIG. 3B shows a section in enlargement along the line IIIB--IIIB in FIG. 3A,
FIGS. 4A and 4B show views of two opposite sides of a gear change means of the gear change device illustrated in FIG. 2,
FIG. 4C shows a section in enlargement along the line IVC--IVC in FIG. 4B, and
FIG. 5 shows a view of a further gear change means of the gear change device mounted on the removal means illustrated in FIG. 2.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The removal device according to the invention shown in FIGS. 1A and 2 comprises a motor 1 with a drive shaft 2, which is connected to a removal means in the form of a cord drum 3 via a gear change device 4, for achieving required torque. From i.e. a spacial point of view this gear change device 4 has been chosen to comprise a planetary gearing with a housing belonging thereto, even though other gear change devices would be possible to use.
The planetary gearing 4 comprises a first gear change means in the form of a sun wheel 5 connected to the drive shaft 2 of the motor, a second gear change means in the form of three planet wheels 6 connected to the cord drum 3 and a third gear change means in the form of a crown wheel 7 adapted to be releasably engaged with the housing of the planetary gearing.
The motor 1 is equipped with a housing 8, which forms a cylindrical chamber 9. One end of the housing 8 of the motor is provided with a wall, which also forms one of the walls for the housing of the planetary gearing and, hence, constitutes an intermediate wall 10 between the chamber 9 of the motor and the chamber 11 of the planetary gearing 4.
The housing of the planetary gearing is formed by the intermediate wall 10 and a casing 12, wherein the chamber 11 of the planetary gearing also houses the cord drum 3. The intermediate wall 10 and the crown wheel 7 delimit a part chamber 11a of the chamber 11 (see FIG. 1C). The housing 8 of the motor 1 is provided with an inlet 13 and an outlet 14 for connection to a source of vacuum (not shown) for operation of the motor.
In the motor's chamber 9 there is arranged a rotor 15 provided with vanes 16 radially movable in relation to an axis A through the rotor 15, which axis is coaxial with the motor's 1 driving shaft 2. The rotor is arranged eccentrically in the motor's chamber 9, so that the vanes 16 are forced to move in a radial direction during rotor's 15 rotation. When connecting the vacuum source, this causes a pressure difference in the motor's chamber 9. The pressure difference acts upon the vanes 16, which in turn force the rotor 15 to rotate.
A cord 17 is at its one end releasably connected to the cord drum 3 by means of a connection means 18. The connection means 18 is arranged such that the cord 17 comes loose from the cord drum 3 if the cord is exposed to a too large, external pulling force when the cord is completely pulled out from the cord drum 3, and is solely held in place by means of the connection means 18. The cord 17 is at its other end intended to be connected to the milking means (not shown), as described in WO 93/00002.
The cord 17 is provided with a stop member in the form of a ball 19. The ball 19 prevents the milking means from hitting the removal means during winding the cord 17. The casing 12 is provided with a catch means 20, through which the cord 17 freely runs, but which does not let the ball 19 through. In the motor's 1 rest position, which will be closer described below, the catch means 20 catches the ball 19 and prevents the cord 17 from being unwound from the cord drum 3. In this way, the whole weight of the milking means can be taken up by the removal device via the catch means 20, when the motor 1 is in said rest position.
FIG. 3A is a front view of the part of the intermediate wall 10, which forms an inner, axially directed wall of the housing 10, 12 of the planetary gearing 4. Centrally in the intermediate wall 10 an opening 21 is formed for reception of the motor's driving shaft 2 with the sun wheel 5 arranged thereon. The intermediate wall 10 is at its periphery provided with a ring 22 of an axially directed friction enhancing means, which ring 22 is coaxial with the opening 21 (see FIG. 3B). The intermediate wall 10 is furthermore provided with two passages 23 for pneumatically connecting said part chamber 11a to the motor's 1 chamber 9. Alternatively, more or less passages than two may certainly be provided in the intermediate wall 10.
In FIG. 4A is shown the planetary gearing's 4 crown wheel 7 seen from the direction which faces away from the intermediate wall 10 and towards the cord drum 3. The crown wheel 7 is provided with a ring 24 of teeth directed radially inwards. In FIG. 4B is shown the side of the planetary gearing's crown wheel 7, which faces the intermediate wall 10. On this side the crown wheel 7 is at its periphery provided with a ring 25 of an axially directed friction enhancing means, which ring is coaxial with the axis of the crown wheel 7 (see FIG. 4C).
The friction enhancing means on the intermediate wall 10 and the crown wheel 7, respectively, are shown in the FIGS. 3A, 3B, 4B and 4C as teeth 22a, 25a having a form substantially similar to a saw tooth, i.e. with non uniformly inclined back rakes, 22b, 25b and 22c, 25c, respectively. The back rakes of each tooth form angles α and β, respectively, with the base of the tooth, α being about 20° and β being about 55°. For reasons explained below these friction enhancing means do not need to consist of teeth 21a, 25a, but could as well on the one hand comprise plain, substantially plane, friction surfaces and on the other hand comprise a mechanical coupling in the form of a pin or the like.
FIG. 5 illustrates an end wall 26 of the cord drum 3, provided with three axes 27, each being provided with a planet wheel 6 with teeth. The planet wheels 6 fit between the crown wheel 7 and the sun wheel 5. Of course the teeth of the crown wheel 7 and the sun wheel 5 fit the teeth of the planet wheels 6.
FUNCTION
On finished milking, which is sensed by a milk flow meter known per se, but not shown, the removal device receives a signal to start the motor 1 for winding the cord 17 onto the cord drum 3. The milking means, which is connected to the cord 17, is hereby pulled away from the teats of the animal.
When the signal is given that the motor 1 shall start, the motor 1 is connected to a source of vacuum, which is suitably the same as the one that operates the milking means. The negative pressure which is thereby created in the chamber 9 of the motor drives the motor 1 such that it rotates. Via the passages 23 in the intermediate wall 10 the chamber 11 of the planetary gearing 4 is pneumatically connected to the motor's chamber 9, such that also the planetary gearing's 4 chamber, like its part chamber 11, is exposed to a negative pressure. In consequence, the crown wheel 7, which is arranged closely to the intermediate wall 10 and in front of the said passages 23, is sucked against the intermediate wall 10 and is anchored on this.
Accordingly, the crown wheel 7 of the planetary gearing 4 works together with the intermediate wall 10 as parts of a coupling device K between the motor 1 and the cord drum 3. It shall be remarked, though, that the crown wheel 7 need not necessarily be anchored in a pneumatical way. The anchorage could as well be achieved in a plain mechanical way by locking by means of pins or by a clamping means of any known kind. Alternatively, such an anchorage would be possible to accomplish in an electro-mechanical way for example by means of a magnet or a solenoid, which pushes or pulls the crown wheel 7 against the intermediate wall (see FIG. B).
The engagement of the crown wheel 7 with the intermediate wall 10 is achieved by means of two differently directed forces, namely a relative to the crown wheel 7, axially acting, retaining force, which is achieved by means of the negative pressure in the part chamber 11a, and a force acting in the circumferential direction of the crown wheel 7, which force is achieved by means of the friction enhancing means. Outgoing from this it is understood that the said engagement can be achieved by means of a frictional engagement between plane friction surfaces. In such a case, the friction enhancing means may consist of plane friction coatings. However, it is desirable that different properties of engagement in different directions of rotation of the crown wheel 7 be achieved and for this reason the differently back raked teeth 22a, 25a are preferred. The reason for this is that the substantially axially directed back rakes 22b, 25b of the teeth on the crown wheel 7 and the intermediate wall 10 together provide a relatively stable hooking of the teeth 22a, 25a in the direction of winding, whereas the more sloping back rakes 22c, 25c form an extra protection against overload for the removal device, since they will without difficulty disconnect by a load directed opposite to the winding direction.
Having the crown wheel 7 anchored on the intermediate wall 10, the sun wheel's 5 rotation of the planet wheels 6 results in rotation of the last mentioned wheels along the crown wheel 7 and about the sun wheel 5, such that the cord drum 3 is turned at a rotational speed which is lower than that of the motor 1. The cord drum 3 thus winds the cord 17 so that the milking means is pulled off the animal's udder. Before the cord is pulled in too far on the cord drum 3, it is stopped by the catch means 20, which catches the ball 19 arranged on the cord 17.
When the milker is to move the milking means and the removal device to the next animal to be milked, the milker looses the connection means from the vacuum source, which results in that the motor 1 assumes the above mentioned rest position and is no longer driven, since there is no longer a negative pressure in the chamber 9 of the motor. Furthermore, no negative pressure will be transmitted through the passages 23 in the intermediate wall 10, which means that the crown wheel 7 is disengaged from the intermediate wall 10 (see FIG. 1C).
When the crown wheel 7 now is freely movable and can move with less friction than the motor 1 on which the sun wheel 5 is arranged, the planet wheels 6 rotate about the sun wheel 5 while this only moves insignificantly or not at all. Accordingly, the cord drum 3 is now disengaged from the motor 1. The ball 19 is still in the catch means 20, which prevents rotation of the disengaged cord drum 3.
When the next animal is to be milked, the milker first disengages the ball 19 from the catch means 20. Owing to the freely movable crown wheel 7 the milker can thereafter pull out the cord from the removal means without resistance from the motor 1 and the planetary gearing 4. The milking means which is now connected to the source of vacuum, will be attached to the animal's teats, where it remains until a signal is given for finished milking.
The invention is not delimited to the embodiment shown here. Hence, the crown wheel 7 may be arranged to be affected by a positive pressure instead of by vacuum. It is also not necessary to use a pneumatic sliding vane motor, but a pneumatic cylinder, an electrical motor or a spiral spring would be possible to use in order to achieve rotation of the cord drum for the winding of the cord.
Similarly anyone of the three said gear change means may comprise anyone of the said wheels, i.e. the sun wheel, the planet wheel or the crown wheel, may be permutedly connected to the motor, the cord drum or the housing of the gear change device. | A device for automatic removal of milking equipment from an animal's udder, comprising a motor (1) and a removal member (3) rotatable by the motor. According to the invention, a coupling device (K) is adapted to keep the removal member (3) operably connected to the motor and to keep the removal means disconnected from the motor, respectively. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. National Stage of International Application No. PCT/EP2012/003265, filed Aug. 1, 2012, which designated the United States and has been published as International Publication No. WO 2013/017270 and which claims the priority of German Patent Application, Ser. No. 10 2011 109 256.4, filed Aug. 2, 2011, pursuant to 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION.
The invention relates to a valve train of an internal combustion engine, having at least one basic camshaft on which a cam carrier having at least one valve-actuating cam is disposed in a rotationally fixed and axially displaceable manner, wherein the cam carrier has a tubular basic element which at least partially accommodates the basic camshaft, on which basic element at least one cam element of the cam carrier, in particular the valve-operating cam, is arranged. The invention furthermore relates to an internal combustion engine and a method of manufacturing a valve train.
Valve trains of the aforementioned type are known in the art. They are used for internal combustion engines, where the operating cycle of gas-exchange valves of individual cylinders of the internal combustion engine can be controlled to improve the thermodynamic property. The at least one cam carrier, which can also be referred to as a cam piece, is arranged on the basic camshaft in a rotationally fixed and axially displaceable manner. The cam carrier is displaced in the axial direction by an adjusting device, which includes a shift gate on the cam carrier and a fixedly arranged actuator, typically in a cylinder head of the internal combustion engine. The actuator has an extendable follower which can be brought into engagement with a helical or spiral groove of the shift gate. At least one valve-actuating cam having an eccentricity, which serves to actuate a gas exchange valve of internal combustion engine at a certain rotational angle of the basic camshaft, is associated with the cam carrier. The valve-actuating cam therefore rotates together with the basic camshaft, so that the gas-exchange valve of the internal combustion engine is operated at least once per revolution of the valve-actuating cam or its eccentricity. The valve-actuating cam preferably cooperates with a roller cam follower of the gas exchange valve by making direct contact therewith.
Preferably, several valve-actuating cams are provided which may be associated with different cam groups. The valve-actuating cams can now vary in the angular position, in the extent in a radial direction and/or in the eccentricity in the circumferential direction. By way of the axial displacement of the cam carrier, the cam carrier can be brought into at least two, for example, in a first and a second actuating position. In the first actuating position, the gas exchange valve is actuated by a first of the valve-actuating cams and in the second actuating position by a second of the valve-actuating cams that are assigned to the same cam group. By the displacement of the cam carrier, in particular the opening timing, the opening duration and/or the stroke of the gas change valve can be selected, in particular as a function of an operating state of the internal combustion engine.
Conventional cam carriers are integrally formed and are made of a metallic solid material, which is subjected to various manufacturing steps. The manufacturing steps include, for example, reaming an internal toothing of the cam support, grinding or turning cylindrical portions of the cam carrier used for rotational support, electron-beam hardening of a surface of the valve-actuating cam as well as gas nitration of surfaces in the area of the shift gate. These manufacturing steps require a not inconsiderable effort and associated costs. In addition, split bearings with two bearing shells or bearing shell halves are required for supporting the conventional cam carriers in the cylinder head of the internal combustion engine which results, on the one hand, in additional manufacturing and assembly costs and causes, on the other hand, increased friction losses in the event of an imperfect pairing of the two bearing shells or bearing shell halves.
To reduce the manufacturing complexity, the cam carrier may have a modular design and may be composed of the basic element and the at least one cam element. The basic element is essentially tubular and at least partially receives the basic camshaft. For this purpose, it encompasses the basic camshaft in the circumferential direction at least partially, preferably completely. The basic element preferably has an internal toothing which engages with an external toothing of the basic camshaft for holding the basic element on the basic camshaft in a rotationally fixed manner. The basic element can be completely drawn together with the internal toothing as a profile and can thus be easily and inexpensively produced. The at least one cam element is arranged on the basic element. The cam element is in particular formed as a cam disc. For example, the valve-actuating cam is embodied as a cam element. However, the cam element may alternatively also be another element, such as the shift gate, a spacer or a locking element. The cam element is preferably made of bearing steel, which is (fine-) punched and ground or reamed on its inner side. Identical or similar cam elements can be ground or reamed together, which allows for an efficient and economical production.
For example, DE 10 2009 022 657 A1 discloses a camshaft for an internal combustion engine. This camshaft consists of a basic shaft having at least one external toothing, and at least one cam carrier which is axially displaceably mounted on the basic shaft and has at least one inner toothing co-operating with the external toothing. The external toothing or the internal toothing is to be made of plastic, wherein the cam carrier made of plastic is molded around the cam elements. Therefore, a modular construction of the cam carrier and the cam elements is already described to some extent. However, the production cost is very high.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a valve train of an internal combustion engine, which obviates the afore-mentioned disadvantages and which can in particular be easily and inexpensively produced and which has at the same time good long-term durability.
This is achieved by the invention with a valve train of an internal combustion engine having at least one basic camshaft on which a cam carrier having at least one valve-actuating cam is arranged in a rotationally fixed and axially displaceable manner. The cam carrier includes a tubular basic element that at least partially accommodates the basic camshaft and on which at least one cam element of the cam carrier, in particular the valve-actuating cam, is disposed. It is hereby provided that at least one torque-transmitting connecting element is disposed between the basic element and the cam element. Unlike in the prior art, the cam carrier is hereby not molded around the cam element, thereby fixing the cam element to the cam carrier. Instead, the connecting element should be disposed between the basic element and the cam element arranged on the basic element, which locks the cam element at least in the circumferential direction relative to the basic element, thereby ensuring a reliable torque transfer from the basic element to the cam element. The connecting element is preferably a sintered element which is hardened or cured. The valve train according to the invention has advantageously a modular design, so that its individual components, i.e. the basic camshaft and the cam carrier or basic element as well as the cam element can be made of a material selected according to the respective load. Material-specific production methods can also be selected for the production. The most advantageous material can therefore be used for each of the elements of the valve train. The modular nature of the valve train is particularly advantageous in one embodiment where the cam element can be fitted onto the basic element.
According to a refinement of the invention, the connecting element at least partially engages in a retaining opening of the basic element and is positively held in the retaining opening at least in the circumferential direction, in particular additionally in the axial direction. The basic element therefore has the retaining opening, which is preferably disposed in a jacket or a jacket surface of the tubular element or extends through the jacket surface. The connecting element then engages at least in sections in the retaining opening, wherein the shapes of the connecting element and the retaining opening are matched such that the connecting element is at least form-fittingly held in the circumferential direction. The retaining opening is preferably formed as a slot extending in the axial direction. Preferably, the connecting element is also held stationary and form-fittingly in the retaining opening in the axial direction. However, the retaining opening may allow to some extent a displacement of the connecting element in the axial direction. In particular, only one retaining portion of the connecting element may be arranged in the retaining opening, while a supporting region of the connecting element rests on a wall of the basic element, in particular the jacket or the jacket surface lies and protrudes in the radial direction over the basic element. At least the supporting region may substantially have the shape of a cuboid. In particular, the shape of the side of the supporting region facing the basic element is matched to that of the basic element so that it substantially rests flat on the basic element. Due to the cooperation of the retaining opening and the connecting element, the connecting element is affixed on the basic element with a rotation lock with respect to an axis of rotation of the basic camshaft.
According to a refinement of the invention, the connecting element engages at least partially in a locating opening of the cam element and is fixedly supported therein in the circumferential direction, while being movable especially in the axial direction. The shape of the locating opening as well as of the retaining opening of the basic element is therefore matched to the shape of the connecting element so as to realize positive retention of the cam element in the circumferential direction. The connecting element is therefore non-rotatably connected to the basic element via the cam element. However, the cam element may be movable in the axial direction in spite of the stationary support in the circumferential direction. This is achieved in particular by having the retaining opening pass completely through the cam element in the axial direction. This allows the cam element to be attached during assembly of the valve train. The cam element can thus be pushed onto the cam carrier. As already explained above, the connecting element is advantageously composed of the holding portion and a support portion. Whereas the holding portion engages in the retaining opening of the basic element, the support portion should at least partially engage in the locating opening of the cam element. Thus, the connecting element engages both in the basic element and the cam element in the radial direction.
According to a refinement of the invention, a plurality of cam elements may be provided, which are secured in the axial direction by abutting contact with adjacent cam elements. It is therefore not intended that the individual cam elements are fastened on the basic element in the axial direction by separate fastening means. Instead, they should be arranged in relation to each other that they are immovable in the axial direction. For this purpose, cam elements arranged at the end of the cam carrier or the basic element are designed, for example, as locking elements. The locking elements are held stationary relative to the basic element in the axial direction, whereby the other cam elements are also held stationary in the axial direction. The locking element is, for example, a hardened sintered element.
According to a refinement of the invention, as viewed in the circumferential direction, the basic element may have only a single retaining opening and/or the cam element may have only a single locating opening. Accordingly, several retaining openings or several locating openings are no longer arranged side by side in the circumferential direction. If several retaining openings or locating openings are present, then these are offset in the axial direction and preferably spaced apart from one another. Alternatively, of course, several retaining holes or locating openings, each with a connecting element disposed therein, may also be provided in the circumferential direction. Preferably, the retaining openings and locating openings are in this case uniformly distributed over the circumference of the basic element or the cam element. In particular, in each case two respective retaining openings or two respective locating openings face each other diametrically.
According to a refinement of the invention, the connecting element commonly forms at least one retaining device for axially securing the cam carrier with respect to the basic camshaft, in particular by having the retaining opening pass completely through a wall of the basic element in the radial direction. The retaining device is used to hold the cam carrier in the axial direction relative to the basic camshaft. However, the axial securement need not be permanent. For example, the retaining device may allow an axial displacement between at least two axial positions. In this case, the retaining device may be particularly designed such that a sufficiently large force must be applied in the axial direction on the cam carrier for exiting one of the axial. positions. The cam carrier moves out of its momentary axial position and enters the adjacent axial: position only upon application of this force. In principle, any number of such axial positions may be provided. However, conventional designs of the valve train have only two or three axial positions.
The retaining device may in particular be designed as a latching device, wherein a latching element may be provided in a radial recess of the basic camshaft. The latching element may be, for example, elastic or spring-biased by a spring element, so that it is urged in the direction of the connecting element. The connecting element has at least one latching recess into which the latching element can latch. Here, a number of latching recesses corresponding to the desired number of axial positions of the cam carrier may be provided which are spaced from each other on the connecting element in the axial direction. The cam carrier can thus be shifted in the axial direction with respect to the basic camshaft, wherein the latching force of the latching device must be overcome during each shift. When no force is applied or when the applied force is smaller than the latching force of the latching device, the cam carrier remains and is reliably secured in its present axial position. For this purpose, the retaining opening completely passes through the wall of the basic element in the radial direction so that the latching element is able to latchingly engage the connecting element through the retaining opening.
According to a refinement of the invention, a plurality of connecting elements may be provided which are spaced apart relative to one another in the axial direction, in particular at the same circumferential position, wherein a camshaft bearing, in particular an undivided bearing seat of the camshaft bearing, is directly seated on the basic element between any two of the connecting elements. The camshaft bearing or its bearing shell does not have a locating opening like the cam element. Instead, these are seated directly on the basic element and preferably over their entire area. This means that the camshaft bearing or the bearing shell is in abutting contact with the basic element. In this way, the bearing forces are uniformly applied to the basic element or the camshaft bearing. The camshaft bearing or the bearing shell is enclosed in the axial direction by the connecting elements or is at least arranged adjacent to a connecting element. The connecting elements and/or the cam elements arranged thereon may come into abutting contact with the camshaft bearing, thereby securing the camshaft bearing in the axial direction relative to the basic element. Advantageously, the connecting elements may be arranged on the basic element at the same circumferential position. However, the connecting elements may also have different, in particular varying, circumferential positions.
According to a refinement of the invention, the camshaft bearing is held stationary in the axial direction by adjacent connecting elements and/or cam elements. As already stated above, connecting elements are preferably provided on both sides of the camshaft bearing. These connecting elements provide a rotationally fixed arrangement of the cam elements on the basic element. The connecting elements or the cam elements should now be arranged with respect to the camshaft bearing so as to hold the camshaft bearing stationary in the axial direction, in particular through abutting contact. The connecting elements and/or the cam elements hence abut the camshaft bearing in the axial direction such that the camshaft bearing is immovable in the axial direction.
The invention further relates to an internal combustion engine with at least one valve train, in particular according to the above embodiments, which has at least one basic camshaft on which at least one cam carrier having valve-actuating cams is arranged in a rotationally fixed and axially displaceable manner, wherein the cam carrier has a tubular basic element which at least partially receives the basic camshaft and on which at least one cam element of the cam carrier, in particular the valve-operating cam, is arranged. At least one torque-transmitting connecting element is disposed between the basic element and the cam element. The valve train may be further improved according to the above description. In principle, it should be emphasized again that the valve train may include any number of cam carriers, which are arranged axially displaceable on the basic camshaft. Each cam carrier has preferably a plurality of cam elements, wherein two of the cam elements may be locking elements and another of the cam elements may be present a shift gate. The additional cam elements are in particular designed as valve-actuating cams.
The invention further relates to a method of manufacturing a valve train, preferably in accordance with the foregoing description, whereby the following steps are performed: providing a basic element, forming at least one retaining opening in the basic element, inserting a torque-transmitting connecting element in the retaining opening, and pushing at least one cam element, in particular a valve-actuating cam, over the connecting element. The retaining opening is preferably formed so as to completely pass through a wall or a jacket of the basic element, which is substantially tubular. The valve train is essentially constructed in accordance with the above description.
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be explained in more detail with reference to the exemplary embodiments illustrated in the drawings, without limiting the scope of the invention. In the drawing show in:
FIG. 1 a diagram of a portion of a valve train of an internal combustion engine, showing a cam carrier composed of a basic element, on which at least one cam element of the cam carrier is arranged,
FIG. 2 a side sectional view of a portion of the valve train in a first embodiment,
FIG. 3 a side sectional view of the valve train in a second embodiment,
FIG. 4 the basic element of the cam carrier,
FIG. 5 two connecting elements which can be inserted into a retaining opening of the basic element,
FIG. 6 an exploded view of a portion of the valve train, showing the basic element, the connecting elements, several cam elements and a camshaft bearing, and
FIG. 7 the portion of the valve train known from FIG. 6 , fully assembled.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a portion of a valve train 1 of an unillustrated internal combustion engine. The valve train 1 is composed of an unillustrated basic camshaft 2 and a cam carrier 3 which is axially displaceable thereon. The cam carrier 3 is composed of a basic element 4 which is substantially tubular and which at least partially accommodates the basic camshaft 2 . Here, the basic element 4 has an internal toothing 5 , which cooperates with an external toothing of the basic camshaft 2 so as to hold the cam carrier 3 on the basic camshaft 2 in a rotationally fixed and axially displaceable manner. The cam carrier 3 has several cam elements 6 in addition to the basic element 4 . One of the cam elements 6 is designed as a shift gate 7 and others of the cam elements 6 are designed as valve-actuating cams 8 . The cam elements 6 disposed on the ends of the cam carrier 3 may operate at the same time as locking elements 9 .
The shift gate 7 is part of an unillustrated actuating device, with which the cam carrier 3 can be displaced on the basic camshaft 2 in the axial direction. For this purpose, the shift gate 7 has a groove 10 which has at least partially a helical shape and with which an actuator of the actuating device cooperates. For this purpose, the actuator has, for example, an extendable tappet adapted for engagement with the groove 10 of the shift gate 7 . This engagement causes a displacement of the cam carrier 3 in one or the other direction in the axial direction based on a current axial position of the cam carder 3 with respect to the basic camshaft 2 .
The valve-actuating cams 8 serve to operate unillustrated gas exchange valves. To this end, they cooperate, for example, with a roller cam follower of the respective gas exchange valve by abutting contact. As can be seen, the valve-actuating cams 8 shown here are eccentric, wherein the eccentricities are present at different angular positions or have different extents in the radial direction and/or circumferential direction. A corresponding stroke, opening time and/or duration of opening of a gas exchange valve thus arises depending on the valve-actuating cam 8 actuated by the gas exchange valve. Through axial displacement of the cam carrier 3 , the gas exchange valve can be actuated by different valve-actuating cams 8 . For example, the cam carrier 3 is displaced as a function of an operating state of the internal combustion engine, so that always the particular valve-actuating cam 8 cooperates with the gas exchange valve for its actuation that results, for example, in an optimum efficiency or optimum performance of the internal combustion engine.
The locking elements 9 provided at the ends of the cam carrier 3 are attached to the cam carrier 3 that that they are secured thereon in the axial direction. Preferably, the other cam elements 6 are simply plugged onto the basic element 4 . They are thus held on the cam carrier 3 in the axial direction by the locking elements 9 . A bearing shell 11 which is part of a camshaft bearing is arranged between two of the cam elements 6 . The bearing shell 11 , like the cam elements 6 , is only plugged onto the basic element 4 and is held in the axial direction by the respective adjacent cam elements 6 and/or the locking elements 9 . The bearing shell 11 is preferably integrally formed, i.e. undivided.
To also secure the cam elements 6 relative to the basic element 4 and the basic camshaft 2 in the circumferential direction, i.e. non-rotatably connecting the cam elements 6 thereto, at least one connecting element 12 is disposed between the basic element 4 and the cam elements 6 . This connecting element 12 is designed to transmit torque, i.e. is non-rotatably connected to both the basic element and the cam elements 6 .
FIG. 2 is a side sectional view of a portion of the valve train 1 . Here, the basic camshaft 2 is also shown on which the cam carrier 3 is arranged in a rotationally fixed and axially displaceable manner. As can be clearly seen, two groups of cams 13 and 14 are provided on the cam bracket 3 . The first cam group 13 includes three valve-actuating cams 8 , which are arranged on the left side of the cam carrier 3 , while the three valve-actuating cams 8 arranged on the right side belong to the cam group 14 . The cam elements 6 arranged directly adjacent to the bearing shell 11 may alternatively also be formed as spacers 15 , which space the valve-actuating cams 8 of the cam groups 13 and 14 from the bearing shell 11 in the axial direction. The term axial direction is to be understood as a direction parallel to the longitudinal axis 16 of the basic camshaft 2 .
As shown in the diagram of FIG. 2 , two connecting elements 12 spaced apart in the axial direction are present. Alternatively, only a single connecting element 12 may be provided, or more than two connecting elements 12 may be disposed on the basic element 4 . The connecting elements 12 engage with retaining openings 17 of the basic element 4 . The retaining openings 17 pass here completely through a jacket 18 of the basic element 4 in the radial direction. The shape of the retaining openings 17 is matched to the respective connecting element 12 such that the connecting element 12 is form-fittingly held in the corresponding retaining opening 17 both in the circumferential direction and in the axial direction. Thus, the retaining openings 17 surround at least a portion of the respective connecting element 12 such that it is fixed in the circumferential direction and in the axial direction. Locating openings 19 of the cam elements 6 are provided on the side of the retaining opening 17 facing the connecting element 12 . The connecting elements 12 also engage in the respective locating openings 19 . The connecting elements 12 thus extend in the radial direction starting from the retaining openings 17 into the locating openings 19 .
The locating openings 19 completely pass through the cam elements 6 in the axial direction, so that the cam elements 6 can be pushed onto the basic element 4 in spite of the connecting elements 12 . The connecting elements 12 thus serve only to secure the cam elements 6 with respect to the basic element 4 in the circumferential direction. Preferably, the connecting elements 12 are each composed of a retaining portion 20 and a support portion 21 . The retaining portion 20 resides substantially completely in the retaining opening 7 , whereas the support portion 21 rests on the jacket 18 and the jacket surface, respectively, and at least partially engages in the respective locating opening 19 . Thus, the connecting elements 12 are designed to transmit torque between the basic element 4 and the cam elements 6 .
At least one of the connecting elements 12 also forms a retaining device 22 for axially securing the cam carrier 3 relative to the basic camshaft 2 . The retaining device 22 is formed in the present case as a latching device, wherein a latching element 24 —which is here spherical—is provided in a radial recess 23 of the basic camshaft 2 . The latching element 24 is urged by a spring element 25 in the direction of the connecting element 12 . The connecting element 12 has in the illustrated embodiment three recesses 26 , in which the latching element 24 can latchingly engage. The illustrated valve train has three adjustable settings, meaning that the cam carrier 3 can be to be moved into three different axial positions with respect to the basic camshaft 2 . In this manner, the cam carrier 3 can be displaced in the axial direction with respect to the basic camshaft 2 , whereby the latching force of the retaining device 22 must be overcome during each move.
FIG. 3 shows another embodiment of the valve train 1 , which substantially corresponds to the embodiment described with reference to FIG. 2 , so that reference is made to the foregoing description. The difference is that the illustrated cam carrier 3 is adjustable only 2-fold, so that only two latching recesses 26 are provided on the connecting element 12 . In addition, only two valve-actuating cams 8 are associated with each group of cams 13 and 14 .
FIG. 4 shows the basic element 4 of the cam carrier 3 . Clearly seen is here the internal toothing 5 for establishing the rotation-locked connection with the basic camshaft 2 (not shown). The retaining holes 17 are provided in the basic element 4 , which are constructed as an oblong hole and extend here in the axial direction or have the greater extent in this direction.
FIG. 5 shows the connecting elements 12 , clearly showing that these are composed of the retaining portion 20 and the support portion 21 . Furthermore, latching recesses 26 can be seen on the connecting element 12 on the right-hand side.
FIG. 6 shows an exploded view of the cam carrier 3 and the elements associated therewith, respectively. The connecting elements 12 are already arranged on the basic element 4 . The bearing shell 11 is disposed between the two connecting elements 12 and fixed in the axial direction relative to the cam carrier 3 due to its arrangement between the two connecting elements 12 . In addition to the basic element 4 and the bearing shell 11 , four valve-actuating cams 8 and the shift gate 7 are shown.
The cam carriers 3 are usually assembled as follows: Initially, the bearing shell 11 is placed on the basic element 4 . Then, the connecting elements 12 are placed on both sides of the bearing shell 11 . Subsequently, two of the valve-actuating cams 8 to the left of the bearing shell 11 and two more of the operating cams 8 to the right of the bearing shell 11 are pushed onto the basic element 4 so that the locating openings 19 of the valve-actuating cams 8 enclose a portion of the connecting elements 12 , in particular their support portion 21 . The shift gate 7 is then also so applied onto the basic element 4 on the right side of the bearing shell 11 , so that its locating opening 19 cooperates with the connecting element 12 . Subsequently, the end-side cam elements 6 , in this case one of the valve-actuating cams 8 and the shift gate 7 , are secured in the axial direction on the basic element 4 . In this way, the other cam elements 6 and the bearing cup 11 are also securely held in the axial direction.
FIG. 7 shows the cam carrier 3 after assembly. The individual elements correspond to those described with reference to FIG. 6 , so that reference is made to the foregoing description.
With the valve train 1 and the cam element 3 described above, a modular design is attained, which enables a simple and inexpensive manufacture of the cam carrier 3 . In particular, the cam carrier 3 can be assembled in modular form so that different series of the valve train 1 can be composed of identical components. | A valve train of an internal combustion engine includes at least one basic camshaft with a cam carrier provided thereupon in a rotationally fixed and axially displaceable manner. The cam carrier has at least one valve-actuating cam as well as a tubular basic element that receives the basic camshaft in at least some sections. At least one cam element of the cam carrier, in particular the valve-actuating cam, is arranged on the basic element. At least one torque-transmitting connecting element is located between the basic element and the cam element. An internal combustion engine having at least one valve train and a method for producing a valve train are also disclosed. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of under 35 U.S.C. §119(e)(1) of U.S. Provisional Application Ser. No. 60/041,108, filed Mar. 19, 1997, entitled “FORMATION ISOLATION VALVE (FIV) WITH TRIPLESS COUNTER OPERATOR”;
This application further claims the benefit under 35 U.S.C. §120 of U.S. patent application Ser. No. 08/646,673, filed May 10, 1996, now U.S. Pat. No. 5,810,087, entitled “FORMATION ISOLATION VALVE ADAPTED FOR BUILDING A TOOL STRING OF ANY DESIRED LENGTH PRIOR TO LOWERING THE TOOL STRING DOWNHOLE FOR PERFORMING A WELLBORE OPERATION”, and U.S. patent application Ser. No. 08/762,762, now U.S. Pat. No. 6,085,845, filed Dec. 10, 1996, entitled “SURFACE CONTROLLED FORMATION ISOLATION VALVE ADAPTED FOR DEPLOYMENT OF A DESIRED LENGTH OF A TOOL STRING IN WELLBORE”.
BACKGROUND
The invention relates to a valve operating mechansim.
In a wellbore, one or more valves can be used to control flow of fluid between different sections of the wellbore. Such valves are typically referred to as formation isolation valves. A formation isolation valve can include a ball valve that is controllable with a shifting tool lowered into the wellbore. For example, the shifting tool can be attached to the end of a tool string (e.g., perforating string). The shifting tool engages a valve operator that is operably coupled to the valve to rotate the valve between the open and close positions.
In addition to use of a shifting tool, such valves can also be operated remotely, such as by application of fluid pressure from the surface to a valve. In addition to valves, other equipment may also be located downhole. Such equipment may also be operable by fluid pressure applied down the wellbore. Thus, a need arises for a mechanism that can prevent actuation of a valve when such fluid pressure is applied to operate the other equipment.
SUMMARY
In general, in one aspect, the invention features an apparatus for operating a valve positioned in a wellbore. The apparatus includes a tubing having a bore and a piston operably coupled to the valve. The piston is moveable from a first position to the second position by predetermined pressure applied from fluid in the tubing bore. A counter mechanism coupled to the piston prevents movement of the piston to the second position until the predetermined pressure has been applied a first number of times.
Other features will become apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a wellbore having a formation isolation valve.
FIGS. 2-4 are diagrams of a formation isolation valve.
FIGS. 5A-5B are a cross-section of portions of the formation isolation valve.
FIG. 6 is a diagram of J slots used in a counter mechanism in the formation isolation valve.
FIG. 7 is a cross-sectional view of a power mandrel used in the counter mechanism in the formation isolation valve.
FIG. 8 is a cross-sectional view of a spline sleeve used in the counter mechanism in the formation isolation valve.
DETAILED DESCRIPTION
Referring to FIG. 1, a wellbore 12 having a vertical section and a deviated section is shown. Casing 6 is cemented to the inner wall of the wellbore 12 . A tubing string 14 , connected to surface equipment, extends through both the vertical and deviated portions of the wellbore 12 . A formation isolation valve (FIV) 18 is connected to the tubing string 14 at a predetermined location. In one embodiment, the FIV 18 includes a ball valve 18 a and a valve operator mechanism 18 b . The operator mechanism 18 b can be actuated to open and close the valve 18 a . When closed, the ball valve 18 a prevents fluid communication between the upper and lower sections of the wellbore 12 .
A tool string (e.g., a perforating string 10 ) can be lowered on a coiled tubing 14 into the bore of the tubing string 14 and through the bore of the FIV 18 . Connected at the bottom end of the perforating string 10 is a shifting tool 16 used to engage the operator mechanism 18 b to actuate the ball valve 18 a . The shifting tool 16 can be used to repeatedly open and close the valve 18 a.
The FIV 18 can be actuated remotely from the surface using fluid pressure communicated down the tubing string 14 to the FIV 18 . By allowing this remote actuation, a trip downhole to open the valve 18 a can be avoided. According to an embodiment of the invention, the FIV 18 includes a counter section 200 (FIG. 5B) that can be set to actuate the valve operator mechanism 18 b after a predetermined number of pressure cycles. One advantage offered by using the counter section 200 is that pressure cycles can be used to activate other equipment downhole or to perform tests without actuating the ball valve 18 a.
Referring to FIGS. 2-4, portions of the FIV 18 , including a tripsaver section and a valve section, are illustrated. FIG. 2 shows the FIV 18 in its initial run-in position, FIG. 3 shows the FIV 18 in its closed position, and FIG. 4 shows the FIV 18 in its re-opened position.
The ball valve 18 a is connected to a ball operator 18 b , which includes a pair of grooves 18 b 1 in which a detent 18 b 3 is disposed. An upward longitudinal movement of the ball operator 18 b (such as in response to engagement of a shifting tool as the tool is being raised out of the wellbore) will cause the detent 18 b 3 to move out of one groove and fall into the other groove of the pair of grooves 18 b 1 . The ball operator 18 b will then rotate the ball valve 18 a from the run-in open position in FIG. 2 to the closed position in FIG. 3 .
The tripsaver section of the FIV 18 includes an operator mandrel 114 , a gas chamber 110 , a power mandrel 122 , a fluid chamber 128 , and a counter section 200 . The gas chamber 110 includes a preselected gas (e.g., nitrogen), which defines a reference pressure. Fluid in the tubing string 14 can be communicated through the FIV bore 108 to the fluid chamber 128 , which applies an upward pressure on the power mandrel 122 . When the fluid pressure exceeds the gas pressure, the power mandrel 122 moves up along with the operator mandrel 114 . When fluid is bled from the tubing string 14 the fluid pressure drops and the power mandrel 122 is pushed back down. Each up and down movement of the power mandrel 122 makes up a cycle. After a predetermined number of cycles, the counter section 200 is activated to allow the bottom of the power mandrel 122 to contact the top part of a latch mandrel 176 in the valve operator 18 b , as shown in FIG. 4 . The downward movement of the valve operator 18 b will cause the ball valve 18 a to rotate from its closed position (FIG. 3) to its open position (FIG. 4 ). This cycled actuation of the ball valve 18 a can be repeated.
In the configuration shown in FIG. 4, the latch mandrel 176 of the valve operator 18 b engages the power mandrel 122 to open the valve 18 a . The counter mechanism 200 acts to engage and disengage the latch mandrel 176 from the power mandrel 122 . The counter mechanism allows engagement of the power mandrel 122 with the latch mandrel 176 after the power mandrel is operated a certain number of up and down cycles. The nitrogen gas provides power for moving the power mandrel 122 down against the tubing pressure.
The nitrogen gas chamber can be pre-charged at the surface to certain pressures to give a desired downhole reference pressure or a separate reference tool can be run which will allow the nitrogen gas reference pressure to equalize with the hydrostatic pressure and then isolate the nitrogen gas reference pressure from the tubing pressure.
Referring to FIGS. 5A-5B, the FIV 18 includes a valve section (containing the valve 18 a and valve operator 18 b ) and a tripsaver section (containing a power mandrel 122 and a counter section 200 ). In FIG. 5A, the top part of the FIV 18 includes a top sub section 106 that has a threaded opening for connecting to the tubing string 14 . The FIV 18 has an axial bore 108 through which a tool string can pass. The top sub section 106 is threadably connected to a first housing section 112 . An operator mandrel 114 is located inside the first housing section 112 . A chamber 110 is defined by the outer wall 118 of the operator mandrel 114 , the inner wall 116 of the first housing section 112 , and the bottom face 134 of the top sub section 106 . The chamber can be filled with nitrogen or other suitable gas to define a reference pressure for remote operation of the FIV 18 . O-ring seals 102 are used to seal the gas chamber 110 .
In FIG. 5B, the operator mandrel 114 is threadably connected to a power mandrel 122 , and the first housing section 112 is threadably connected to a middle housing section 136 . A fluid chamber 128 is defined between the inner wall 140 of the middle housing section 136 and the outer wall 138 of the power mandrel 122 . The fluid chamber 128 fills with fluid that exists in the bore 108 of the FIV 18 . Thus, fluid pressure applied from the surface can be communicated through the bore of the tubing string 14 to the fluid chamber 128 and applied to the area formed between the O-ring seal 124 and the inner diameter of the operator mandrel 114 . The bottom surface 142 of a flange portion 126 of the power mandrel 122 initially sits on a shoulder 150 of a protruding section 156 of a spline sleeve 152 .
If the fluid chamber pressure exceeds the reference pressure of the gas chamber 110 , then the power mandrel is pushed up (or to the left of the page on FIG. 5 B). The power mandrel 122 can travel the distance defined by a gap 146 until the top surface 148 of a flange portion 126 bumps up against the bottom face 134 of the first housing section 112 . An O-ring seal 124 prevents fluid communication between the fluid chamber 128 and the gas chamber 110 , and an O-ring seal 144 prevents fluid communication from outside the housing of the FIV 18 .
When the power mandrel 122 is pushed to its up position, half a power cycle has occurred. When fluid pressure in the FIV bore 108 is next bled off at the surface until the gas chamber reference pressure exceeds the fluid chamber pressure, the power mandrel 122 drops back down until the bottom surface 142 of a flange portion 126 hits the shoulder 150 defined by a protruding section 156 of the spline sleeve 152 . Each up and down motion of the power mandrel 122 defines one cycle of the counter section 200 .
After a predetermined number of cycles, the counter section 200 of the FIV 18 is activated to allow the power mandrel 122 to move down past a protruding section 156 of the spline sleeve 152 . The spline sleeve 152 is rotatable with respect to the power mandrel 122 . Each up and down cycle of the power mandrel 122 causes the spline sleeve 152 to rotate a certain distance. In one embodiment, as shown in FIG. 7, the power mandrel includes three flange portions 126 A-C. As shown in FIG. 8, the spline sleeve 152 includes three protruding sections 156 A-C. After a predetermined number of cycles, gaps 158 A-C between the protruding sections 156 A-C line up with the flange sections 126 A-C, allowing the power mandrel 122 to move down past the protruding sections 156 toward the shoulder 137 of the middle housing section 136 (after shear pins 120 are sheared as discussed further below).
A J-slot pin 130 is inserted through the spline sleeve 152 to move in a step-wise fashion along J slots defined in the outer wall 138 of the power mandrel 122 as the spline sleeve 152 is rotated. As the spline sleeve 152 rotates, the J-slot pin 130 travels along a path defined by the J slots generally along the circumference of the power mandrel outer wall 138 , as shown in FIG. 6 .
As illustrated in the different views of FIGS. 6 and 7, there are 10 J slots 161 , 162 , 163 , 164 , 165 , 166 , 167 , 168 , 169 , and 170 in the power mandrel 122 . J slots 161 - 169 are of the same length (length A), and J slot 170 is of a longer length (length B). The shorter length J slots allow movement of the power mandrel 122 in an up and down fashion along length A, but such movement does not allow the power mandrel to engage the ball valve operator 18 b . The J-slot pin 130 of the rotating spline sleeve 152 is rotatingly urged along adjacent J slots with each cycle of the power mandrel 122 . The single long length counter track engagement J slot 170 is designed to allow sufficient movement along length B of the power mandrel to allow the power mandrel 122 to engage the valve operator 18 b sufficiently to operate on the valve 18 a . A fixed J-slot pin 132 contained in the first housing section 112 remains tracking in the engagement slot 170 as the spline sleeve 152 rotates and the J-slot pin 130 moves between different J slots.
In operation, the J-slot pin 130 can initially be located in slot 161 A. When the power mandrel 122 is pushed up by fluid pressure, the J-slot pin 130 travels along the path from the slot 161 A to 161 B. When the power mandrel 122 moves back down again after fluid pressure is removed, the J-slot pin 130 travels along the path defined from slot 161 B to slot 162 A. This is repeated until the J-slot pin 130 reaches slot 169 B. On the next down cycle of the power mandrel 122 , the flange portions 126 A-C line up with the gaps 158 A-C, which then allows the J-slot pin 130 to travel along the extended slot 170 A as the power mandrel 122 moves down toward the shoulder 137 of the middle housing section 136 .
When the operator mandrel 114 moves down to actuate the valve 18 a , an opening 101 in the operator mandrel 114 moves down to allow the gas chamber 110 to communicate with the inner bore 108 of the FIV 18 . As a result, the gas (e.g., nitrogen) in the chamber 110 escapes through the opening 101 . The chamber 110 then fills up with tubing fluid to equalize pressure above and below the operator mandrel 114 . This allows a shifting tool to open and close the valve 18 a in subsequent operations.
To ensure that the pressure in the FIV bore 108 is at or below the formation pressure under the ball valve 18 a , shear pins 120 connect the operator mandrel 114 to a sleeve 121 . When the operator mandrel 114 and power mandrel 122 initially move downwardly, the sleeve 121 hits against a shoulder 123 in the first housing section 112 to prevent further movement of the operator and power mandrels. By bleeding away the tubing string bore pressure (and thus the FIV bore pressure), a sufficiently large pressure differential can be created between the gas chamber pressure and the fluid chamber pressure in the FIV 18 to shear the shearing pins 120 . Once the shearing pins 120 are sheared, the operator mandrel and power mandrel can drop down. By ensuring a low FIV bore pressure less than the formation pressure below the valve 18 a , damage can be avoided to the formation below the valve 18 a when the valve 18 a is reopened.
If desired, the tubing bore fluid pressure can also be maintained at a high enough level that the shearing pins 120 are not sheared. As a result, down movement of the power mandrel 122 to engage the valve operator 18 b is prevented. If the tubing bore fluid pressure is not dropped low enough, then the valve 18 a is not opened. This effectively resets the counter mechanism 200 on the next pressure up cycle. To activate the power mandrel again, the predetermined number of cycles must be reapplied to the counter mechanism.
The down movement of the power mandrel 122 causes its bottom part 172 to contact the top part of the latch mandrel 176 . This moves the latch mandrel 176 to thereby actuate the ball valve 18 a.
The tripsaver counter mechanism 200 in the FIV 18 allows one to, for example, pressure test tubing against the closed ball valve multiple times without cycling the ball valve open. This provides a great deal of flexibility downhole to alter the planned operations if required.
Alternatively, the valve can be closed and opened with a shifting tool run on the tubing, wireline, or coil tubing giving a redundant means of operating the valve to tubing pressure. The shifting tool is run at the end of the tool (e.g., perforating gun) string and includes a bi-directional collet and upper and lower centralizers. Pulling out of the hole the shifting tool collet engages with the latch profile and pulls the latch out of the detent closing the ball valve. The shifting tool disengages from the latch fingers once the ball is fully closed. Running in the hole the shifting tool collet engages with the latch profile and pushes the latch out of detent opening the ball valve. The ball valve opens every time the shifting tool is run through it and closes when pulled out of it. A uni-directional collet with shifting tool is run in to open the ball valve in case it can not be opened with tubing pressure. This collet will open the ball running in but does not close the ball pulling out. A detailed description of how a shifting tool actuates a ball valve is provided in the following applications, which are both owned by the same assignee of the present application and both incorporated herein by reference: U.S. patent application Ser. No. 08/646,673, entitled “Formation Isolation Valve Adapted for Building a Tool String of any Desired Length Prior to Lowering the Tool String Downhole for Performing a Wellbore Operation,” filed on May 10, 1996; and U.S. patent application Ser. No. 08/762,762, entitled “Surface Controlled Formation Isolation Valve Adapted for Deployment of a Desired Length of a Tool String in Wellbore,” filed on Dec. 10, 1996.
An optional spring loaded lock 133 (FIG. 5B) can be included in the FIV 18 adjacent the power mandrel 122 . When the power mandrel 122 moves down to engage the latch mandrel 176 of the ball operator 18 b , the spring loaded lock is pushed into a groove 135 initially located higher up on the power mandrel 122 . Once locked, the power mandrel 122 cannot be moved by subsequent operations, thereby locking the valve 18 a in an open position.
The FIV according to embodiments of the invention has many uses and advantages. For example, some wells are completed with other than cemented liner, i.e. the reservoir is exposed while top hole completion is run. In such a case, the formation might be damaged beyond repair due to the invasion of the completion fluid. If an FIV is installed at the top of the liner, it can be used as a barrier to keep the reservoir section isolated and protected. If the FIV is set in shallow depth up to 600 meters, it can be controlled via a control line with nitrogen, then the valve can be used as a second safety valve.
The FIV has an advantage that it can be tested from above as well as from below because it is a ball valve as compared to flapper-type safety valve. Some of the traditional wireline works can be avoided or minimized by using appropriate downhole valve technology which will reduce rig time, cost and risks associated with wireline works. As multi-lateral wells become common with the advancement of drilling and completion technologies, full bore ball valves will be an important component for well control, intervention, production and reservoir management in intelligent completion systems used in such multi-lateral wells.
Additionally, the FIV can be used to isolate wellbore sections so that a wellbore tool string of any desired length may be made up in the first section prior to opening the valve. The tool string can be lowered into the second section of the wellbore for performing one or more wellbore operations downhole in the second section.
Further, the FIV according to embodiments of the present invention can be used for isolating the formation from a portion of the wellbore above the formation by, e.g., positioning in a wellbore above the formation a valve assembly having a fluid conduit capable of the passage of tools therethrough and into the zone to be isolated and capable of allowing or preventing fluid communication within the wellbore between the wellhead and the formation.
Embodiments of the invention may also have one or more of the following advantages. By using a trip saver section, tubing pressure can operate the valve, thereby avoiding the need for a trip downhole for valve operation. The counter section associated with the valve allows other operations to be performed downhole before the valve is activated. The valve is multi-cycled and can be opened and closed as often as desired. Even after activating the trip saver, the valve can be subsequently opened and closed mechanically by a shifting tool.
Other embodiments are within the scope of the following claims. For example, although a specific valve mechanism is described, other types of valves and valve operator mechanisms can be used with a counter section 200 according to an embodiment of the invention.
Although the present invention has been described with reference to specific exemplary embodiments, various modifications and variations may be made to these embodiments without departing from the spirit and scope of the invention as set forth in the claims. | Apparatus and method for operating a valve positioned in a wellbore. The apparatus includes a tubing having a bore and a piston operably coupled to the valve. The piston is moveable from a first position to the second position by predetermined pressure applied from fluid in the tubing bore. A counter mechanism coupled to the piston prevents movement of the piston to the second position until the predetermined pressure has been applied a first number of times. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
None
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
This invention relates to an ironing board, and in particular an ironing board built into a piece of furniture. The ironing board has a cabinet face covering the enclosure used to store the ironing board, and rails to extend and retract the ironing board out of and into the enclosure.
Ironing boards that are foldable or telescoping and are incorporated into furniture have been described, and include: U.S. Pat. No. 5,444,928 issued on Aug. 29, 1995, to Sagel; U.S. Pat. No. 5,241,766 issued on Sep. 7, 1993, to Waltz et al.; and U.S. Pat. No. 3,641,947 issued on Feb. 15, 1972 to Finney. These ironing boards have a seam on the working surface where the ironing board is folded, thus potentially causing unwanted creases to be formed in the article of clothing or material being ironed.
Previous ironing boards that are stored in cabinet like enclosures and are not folded are known in the art and include: U.S. Pat. No. 5,452,531 issued on Sep. 26, 1995 to Graville et al.; U.S. Pat. No. 4,049,332 issued on Sep. 20, 1977 to Bourdeaux; U.S. Pat. No. 5,241,766 issued on Sep. 7, 1993 to Waltz et al.; and U.S. Pat. No. 2,227,786 issued on Jan. 7, 1941 to LaFee. Each of these ironing boards is incorporated into furniture in a relatively permanent way, and removal of the ironing board assembly cannot be accomplished without the use of tools.
BRIEF SUMMARY OF THE INVENTION
An improved ironing board assembly is provided which is removably situated in a piece of furniture such as a dresser, cabinet or the like. The ironing board resides in a recessed enclosure, and is extendible from the enclosure by way of a pair of standard, heavy duty cabinetry rails. The ironing board has an attached cabinet face including handles to cover the enclosure's front opening when the ironing board is retracted. The ironing board is removable from the enclosure, allowing the user to replace the ironing board assembly with a differently sized ironing board or a drawer if desired, without using tools.
Among the several objects of the present invention are: The provision of an ironing board that may be stored within a piece of furniture when not in use;
the provision of an ironing board assembly that may be easily removed from an enclosure within a piece of furniture and replaced with a different ironing board or a drawer;
the provision of an ironing board that has an attached cabinet face cover;
the provision of an ironing board that is simple and inexpensive to manufacture;
and the provision of an ironing board that is sturdy and easy to use.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the drawings, FIG. 1 is a view in side elevation of an ironing board of the present invention in a retracted state;
FIG. 2 is a top plan view of an ironing board of the present invention in a retracted state;
FIG. 3 is a top plan view of an ironing board of the present invention in an extended state;
FIG. 4 is a bottom plan view of an ironing board of the present invention in a retracted state;
FIG. 5 is a view in side elevation of an ironing board of the present invention in an extended state; and
FIG. 6 is a front view of a an ironing board of the present invention in an extended state.
DETAILED DESCRIPTION OF THE INVENTION
Referring now the drawings, and in particular to FIGS. 1, 2 and 4, an ironing board assembly 1 of the present invention comprises an ironing surface 2, a set of two rails 19 and 20, and a cabinet face 4 attached to ironing surface 2 by arms 9 and 10. Ironing surface 2 is essentially conventional, having a tapered neck portion 6 at one end and a substantially rectangular portion at the other end. As with most conventional ironing surfaces, ironing surface 2 has rounded comers. The ironing board assembly 1 is encased in a recessed enclosure 3 that is formed as a rectangular box with an open front end. The enclosure 3 is suitable for installation in an existing cabinet, or may be formed as a part integral with a custom made cabinet or dresser. Cabinet face 4 covers the open end of enclosure 3 when the ironing board 1 is in a retracted state. Cabinet face 4 has handles 5 and 7 with which to pull cabinet face 4 forward, extending ironing surface 2 out of enclosure 3 Ironing surface 2 is slideably extendible from enclosure 3 on rails 19 and 20.
Referring now to FIG. 3 and FIG. 4, Rails 19 and 20 have fixed portions 21 and 22 that are attached to enclosure 3 by way of brackets 17 and 18 respectively, the brackets held to the enclosure by screws or glue or the like, and extendible portions 23 and 24 that are attached to ironing surface 2 by brackets (not shown). Rails 19 and 20 are preferably formed with recessed grooves or channels 25 and 26, with extendible portions 23 and 24 slideably positioned within grooves 25 and 26. Stops 27 and 28 are incorporated into rails 19 and 20 respectively, and serve to prevent the ironing board surface 2 from being pulled completely out of grooves 25 and 26 and enclosure 3. Stops 25 and 26 are releasable, so that the ironing board and extendible rails 23 and 24 may be removed. The releasable stops 27 and 28 are conventional and well known in the cabinetry art.
Adjustable arms 9 and 10 are attached to both the cabinet face 4 and the ironing surface 2. Referring back to FIG. 1, Bracket 14 of arm 9 is attached to the underside of ironing surface 2. Bracket 12 of arm 9 is attached to cabinet face 4. Adjustable arms 9 and 10 are formed with a joint 11 so that when ironing surface 2 is extended by pulling handles 5 and 6 toward the user, cabinet face 4 is moved in a direction beneath the ironing surface 2 by means of joint 11.
In the preferred embodiment of the present invention, the joint 11 is a simple bracket 12 positioned toward the rail 19 of the ironing surface 2, and to arm 9. Another joint 13 is similarly positioned at rail 20 under ironing surface 2 and attached to arm 10. Brackets 12 and 13 are riveted to rails 19 and 20, respectively, and pivot about the rivets. When the cabinet face 4 is pulled away from enclosure 3, the arms 9 and 10 are moved in a downward direction to a point underneath the ironing surface 2, thus moving cabinet face 4 out of the way of ironing surface 2.
It is contemplated that in any embodiment cabinet face 4 is integral with ironing surface 2, being attached by way of arms 9 and 10 with an intermediate joint 11 so that cabinet face 4 is moved underneath ironing surface 2. The provision of an integral cabinet face makes it possible for the user to remove the entire ironing board assembly 1 from the fixed rails 21 and 22 by releasing stops 27 and 28 respectively, thus allowing the installation of a different ironing surface, as in an ironing surface adapted for use in ironing shirt sleeves for example, or a utility drawer into the fixed rails 21 and 22 without requiring the use of tools.
A cup 30 is preferably attached toward the rear of the ironing surface, that is the section opposite the neck of the ironing surface. The cup may be used to hold spray starch, water or other useful canisters.
A wire keeper 32 is positioned toward the rear of ironing surface 2 at the side facing the cabinet recess. Wire keeper 32 pivots from a lower position which is parallel to the plane of the ironing surface 2, to an upper position which is perpendicular to the plane of ironing surface 2. Wire keeper 32 is well known in the ironing board art.
Referring to FIG. 4 and FIG. 5, an optional leg 36 has an attached end 38 toward the neck portion 6 of ironing surface 2 and a free end 39. Attached end 38 of leg 36 is attached to ironing surface 2 by means of joint 37 at attached end 38. When ironing surface 2 is in a position retracted within enclosure 3, the leg 36 is positioned parallel to the plane of ironing surface 2, that is to say the leg 36 is substantially horizontal. A keeper 40 holds leg 36 in place when leg 36 is parallel to ironing surface 2. Keeper 40 is a flat sheet of metal that is riveted to the under side of ironing surface 2, so as to be movable from a position covering leg 36 to a position uncovering leg 36. When the ironing surface 2 is extended from enclosure 3, the leg 36 is moved from the horizontal position to a position perpendicular to the plane of the ironing surface 2 to a distance sufficient to touch the ground, thus providing greater stability to ironing surface 2. Leg 36 is preferably made in two sections, an outer section 43 and an inner section 45 that telescopes from outer section 43. A plurality of openings 46 in outer section 43 of leg 36 receive a spring biased stop 48, so that inner section 45 is removably fixed at a number of pre-selected positions, depending upon the desired height of the leg 36.
In view of the foregoing, it will be seen that the several objects of the invention are achieved and other advantageous results are obtained.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative, and not in a limiting sense. | A removable ironing board (2) enclosed in a piece of furniture (1). The ironing board (2) is mounted on extendible rails (19 and 20) so that the ironing surface (2) projects out of the enclosure (3) when in use. A panel (4) is attached to the ironing surface(2), and is movable to a position underneath the ironing surface (2) when the ironing surface (2) is extended. The ironing board (2) may be replaced with a differently shaped ironing surface, or removed from the piece of furniture and the enclosure (3) used to house a drawer. | 0 |
FIELD AND BACKGROUND OF THE INVENTION
This invention relates generally to separation of solids from liquids by filtration and in particular to horizontal belt filters in which an endless belt of filter medium is moved intermittently over one or more physically fixed vacuum filtration sections thence to cake discharge and return to filtration.
The type of horizontal belt filter with which this invention is concerned employs a series of fixed vacuum pans over which only the filter medium moves intermittently. One such filter is disclosed in U.S. Pat. No. 3,870,641 in which an endless belt filter medium is moved intermittently (indexed) over the vacuum pans with all movement of the filter medium being effected by a combination that includes one or more continuously rotating drive rollers in contact with the belt and at least two separate, but coordinated shiftable rollers. Vacuum is applied to the belt for preset filtration cycles but released for indexing of the belt.
Prior designs of this type filter have been quite successful and are in wide use, but they suffer from the disadvantage of excessive belt wear, stretching and power consumption on account of the continuously driven rollers and indexing systems employed. Also, the use of separate shiftable rollers for indexing requires a complex control system to coordinate the rollers; and continuously driven rollers wear the belt. Such systems are hard on the filter belt and require much operator attention. Additionally, such prior designs have not provided any reliable ways or means to functionally separate adjacent steps such as form, drain, wash, etc.
SUMMARY OF THE INVENTION
The primary object of the invention is the provision of a horizontal belt filter in which an endless belt filter medium moves by indexing over a stationary filtration section that is comprised of one or more liquid collecting pans that are connected to a source of relatively lower pressure for filtration. The relatively lower pressure may be a vacuum or in the case of an enclosed pressure filter, a reduced pressure zone such as atmosphere. In this application the term vacuum pan includes any relatively lower pressure.
Another object is the provision of a filter of the type described in which all rollers are non-driven idler rollers, the filter belt is advanced through the filter solely by shifting of rollers to effect indexing thereby eliminating the problems attendant upon driven rollers.
Another key object is the provision of a belt indexing system that includes two shiftable rollers mounted in fixed spaced relationship to each other for simultaneous coordinated movement by the same mechanism.
A further object is the provision of means to suspend the filter belt on an air cushion for indexing thereby substantially eliminating destructive tension and rubbing on the belt.
A still further object is the provision of means temporarily defining on the filter belt successive adjacent, but functionally separate zones corresponding to the filtration steps being carried out.
Another very important object is the provision of a filter attaining the foregoing objects while conducting filtration on a substantially continuous basis.
BRIEF DESCRIPTION OF INVENTION
In accordance with the invention, the filter comprises a stationary, usually horizontal, filter section provided with suitable drainage decks and connected to a vacuum or other relatively lower pressure as required for filtration. An endless belt filter medium is trained to pass across the filter; and a series of parallel idler rollers are provided to carry the belt from the filter section successively through a cake discharge section, a belt wash section and return to the filter section for passage therethrough.
Integral with the roller system is a unique belt indexing system in which, during periods when no vacuum is applied, the belt is indexed (advanced) a finite distance, vacuum is applied and, while filtration proceeds, the belt advance mechanism is reset for the next cycle concomitantly with discharge of filter cake.
The filter includes the usual filtration functions such as form, dewater, rinse and/or dry through which the belt is indexed. To separate the filtration functions, a plurality of adjacent vacuum pans are provided and inflatable transverse dams are positioned above the belt over the walls of adjacent pans. When the belt is stationary, the dams are inflated whereupon they contact the belt surface and, in combination with the underlying vacuum pans, functionally divide the belt surface according to the steps involved.
The cycles are timed. Typically, a filtration period between indexing is 30 seconds during which time vacuum is applied to the belt on the vacuum pans. Feed is supplied to the form section while dewatering, washing, or drying proceeds in the other sections.
At the end of each cycle, vacuum is released, a slight positive air pressure is applied from the pans beneath the belt thus floating it. While floated, the belt is rapidly indexed to advance it a predetermined distance. Vacuum is then reapplied and the cycle is repeated. Indexing of the belt while it floats on an air cushion is important. It virtually eliminates belt wear and makes indexing effortless.
In accordance with this invention, the belt indexing mechanism is the sole means by which the filter belt is advanced through the filter. All rollers about which the belt is trained are journaled for idling only. The indexing mechanism comprises two idler rollers spaced apart in fixed relationship on a common carriage or frame that is mounted for shifting. The two rollers, herein called first and second indexing rollers, are also positioned in a particular but variable relationship with other rollers in the system. The shiftable carriage is positioned so that the first indexing roller is adjacent the point of belt exit from the filtration section and the second indexing roller is positioned downstream thereof in the path of the belt return run. At least one idler fixed-position roller is located in the belt return path between the first and second indexing rollers. A first brake or clamp is provided to lock the belt downstream from the filter section against any reverse linear motion as the belt is indexed. While the first brake is on, the carriage and both indexing rollers are shifted. As a result, the first indexing roller moves a finite distance away from the discharge end of the filter section; and a section of belt is indexed (advanced) across the vacuum pans an equivalent distance. Depending on the system configuration, this distance may be less than, equal to, or greater than the distance the indexing roller moves away from the vacuum pan.
Because both indexing rollers are in fixed relationship on the carriage, when the first indexing roller moves, the second indexing roller also moves the same distance in the same direction. Another fixed-position roller is spaced downstream from the second indexing roller so that, on belt advance, the second indexing roller moves toward the fixed roller. This movement shortens the belt between these rollers a distance equivalent to the belt advance across the vacuum pans. This forward indexing is done rapidly. After indexing, vacuum is reapplied through the pans thereby locking the belt against travel. At the same time the first brake downstream from the first indexing roller is released. Thereafter, with vacuum still applied, the common frame with both shiftable rollers is pulled or retracted slowly in the opposite direction so that the first indexing roller moves back toward the filter section while the second moves in the same direction which takes it away from its associated fixed-position roller. When retraction occurs, the length of belt on the upper reach while includes the filter section is shortened as the first indexing roller retracts toward the vacuum pans; and at the same time, reverse movement of the second indexing roller away from the adjacent fixed-position roller increases the belt length between those rollers on equivalent amount. Upon completion of retraction, a section of belt is, in effect, stored upstream from the filter section for use in indexing.
By incorporating both indexing rollers in a single shiftable carriage, only a single actuator, such as a ram, operable only on the carriage is required to effect belt indexing. The single carriage is important because it fixes permanently the spaced relationship between the two indexing rollers and eliminates the need for separately controlled indexing rollers. Thus, any change in the length of one run of the belt is automatically and precisely compensated for by an offsetting change in the other run of the belt.
Included in the system is a tension roller which maintains a uniform tension on the belt by taking or giving up nominal slack as required during operation. An alignment roller assembly is also provided. In the preferred embodiment, both of these rollers are located downstream in the direction of belt travel from the second indexing roller, but are upstream from the filter section. This is desired because the alignment roller works best on the belt during rapid movement on forward indexing.
It is important that the filter belt is never subjected to frictional engagement with driving rollers. Instead, the belt moves only with idlers. In this way belt wear due to slippage between rollers and belt has been substantially eliminated.
In order that the invention may be more readily understood and carried into effect, reference is made to the accompanying drawings and description thereof which are offered by way of example only and not in limitation of the invention, the scope of which is defined solely by the appended claims including equivalents embraced therein.
BRIEF DESCRIPTION OF DRAWINGS
In the drawings:
FIG. 1 is a side elevation of a horizontal belt filter embodying the invention.
FIG. 2 is a top elevation of the indexing rollers and frame embodied in the filter shown in FIG. 1.
FIG. 3 is a side view taken as looking in the direction of arrows 3 in FIG. 2.
FIG. 4 is a partial sectional view taken in the plane of 4--4 of FIG. 3 looking in the direction of the arrows
FIG. 5 is a simplified side view showing the filter when the belt is ready for indexing. For clarity, many components have been omitted.
FIG. 6 is a view like FIG. 5 but illustrates the filter just after the belt has been indexed.
FIG. 7 is a view similar to FIGS. 5 and 6 but with the indexing mechanism partially retracted.
FIG. 8 is a partial section taken in the plane of line 8--8 of FIG. 1 looking in the direction of the arrows
FIG. 9 is a partial side sectional view showing one of the inflatable dams of the invention overlying the filter belt with the dam deflated and thus retracted.
FIG. 10 is a view similar to FIG. 9, but with the dam inflated.
FIG. 11 is a partial top view of the alignment roller assembly.
FIG. 12 is a sectional view of one of the vacuum pans and filter belt.
FIG. 13 is a diagram illustrating the basic functions of the indexing system.
DETAILED DESCRIPTION OF INVENTION
The filter comprises a main frame on which are mounted one or more vacuum pans 11. The pans have perforated, grid-like tops 12 adapted to support a suitable endless belt filter medium 13 while permitting the passage of air and liquid. A suitable feed distributor is located above the belt over the first of the vacuum pans. Each vacuum pan is equipped with a bottom valved outlet conduit 14 for withdrawal of air and filtrate. A branch conduit 15 is provided for admitting pressured air. The filtrate outlet conduit 14 will connect through a conventional receiver to an usual vacuum source while the pressured air inlet 15 will connect through a suitable timed valving system to a source of pressured air.
The filter belt is trained about a plurality of idler rollers each of which is at least as wide as the belt itself. These rollers include suitably mounted rollers to maintain uniform nominal tension on the belt and to keep it in proper alignment.
In accordance with this invention, a pair of idler rollers, referred to as first and second indexing rollers, 17 and 21, are mounted on a rigid but shiftable common frame or carriage 23. This arrangement is the basis for a unique belt indexing system which is the sole driving force for advancing the filter belt through the filter. Since all the rollers are idlers only and none are driven there is essentially no slippage to wear the belt surface. Additionally, since both indexing rollers move together there is no need to coordinate separate roller positions.
Referring especially to FIG. 1 and reading counterclockwise in the direction of belt travel from the upper left end of the filter, the rollers are numbered 17 through 22 inclusive, and 28-30. A supplemental roller 31 is provided above the belt to guide its return to the vacuum pans. Rollers 17 and 21 are respectively the first and second indexing rollers. Both are idlers and are mounted on the carriage 23 which rests on and is guided by horizontal rails 24 (See FIG. 4). The carriage is connected to a ram 25 by which the assembly of carriage and rollers is moved to the left to index the belt forward toward the discharge position at the same time pulling a clean belt section onto the vacuum pans. Thereafter, the carriage and rollers are retracted slowly to reset the system and at the same time discharge cake and effect belt wash.
Rollers 18-19 guide the belt between wash sprays immediately following cake discharge. Thereafter, the belt passes around another idler 20 thence over the second shiftable idler 21 and a fixed-position roller 22. The ram indexes the frame and rollers rapidly in one direction to advance the belt then retracts the assembly (carriage and indexing rollers) slowly. Roller 22 is positioned downstream (in the direction of belt travel) from the second indexing roller a distance slightly greater than the travel of the carriage when the ram extends.
During rapid forward indexing of the belt it is necessary to clamp the belt against reverse movement upstream over the first indexing roller 17. This is accomplished by a pivotal clamp 26 and a ram 27 adjacent the roller 20. The ram 27 forces the pivoted member against the roller 20 to lock the belt against movement.
Roller 28 is for belt alignment while roller 29 is a tension roller; and roller 30 is a return roller. As best illustrated in FIG. 11, the alignment roller is adjustable at both ends by means of a ram 34 which pivots the roller bracket 35 about a center pivot 36 to cant the roller 28 with respect to the belt movement path to maintain or correct alignment in accordance with known practice.
Nominal tension on the belt is maintained by a roller 29 which is journaled in suitable bearings 37 in slidable blocks connected to ram 38 in turn maintained under desired constant
The final fixed-position roller 30 adjacent the feed end of the filter guides the belt back over the vacuum pans. This roller 30 along with the final media guide roller 31 initially spaces the belt a little above the top of the vacuum pans. A plate could be used in place of the roller 30, if desired. Also, belt indexing may be further facilitated by positioning the indexing roller 17 to normally hold the belt above the grids at the point of exit.
As shown in FIG. 8, the vacuum pans have upwardly sloping side wings 32 above the pan proper. The belt rests on the drainage surface 12 of the pans 11 and extends up onto the wings. This insures that all feed is retained on the belt.
The final media guide roller 31 is of length about equal to the width of the vacuum pans. As the belt passes under the roller, it is properly positioned just above (almost touching) the grid so that when vacuum is applied, the belt is pulled onto the drainage grids but when there is no vacuum the belt is loose relative to the grid.
Operation of the system is best shown in FIGS. 13 and 5-7.
The simplest form of the system is illustrated in FIG. 13 in which the same components are given the same reference numerals as in FIGS. 5-7. Essentially, the system comprises an endless belt that travels through a working run that includes a filter section, and a return run that conducts the belt leaving the filter section through necessary cake discharge, belt wash, alignment, etc. thence back to the filter section.
The filter section includes vacuum pans 11 over which the belt 13 passes. The belt return run includes the belt and both the first and second indexing rollers 17 and 21 which are on the carriage 23. The belt leaving the first indexing roller 17 passes around a fixed-position roller 20 that is located downstream from the first roller 17 and between it and the second indexing roller 21. The roller 20 is below the vacuum pans and below both indexing rollers. From the roller 20 the belt moves over the second indexing roller 21 thence in a direction generally back toward the first indexing roller then around a fixed-position roller 22 and back toward the feed end of the filter section at roller 30.
In the position as shown in solid lines in FIG. 13, the unit is ready for indexing. To index, the vacuum is turned off and the first brake 26 is applied to lock the belt against movement. Ram 25 (FIG. 6) is rapidly extended full length to move the carriage 23 and rollers 17 and 21 to the positions shown in dotted lines. This pulls the belt over the vacuum pans a distance equivalent to the ram extension. In the embodiment illustrated, the belt indexes a distance greater than the ram extension. The belt length needed to permit indexing is made available by the movement of the second indexing roller 21 toward the idler roller 22. The net result of this movement is to transfer belt lengths between working and return runs as needed to satisfy the indexing movement.
Once the indexing has been completed the first brake 26 is released and the second brake (which may be vacuum) is applied. Then the system is actuated to slowly retract the ram so that both rollers 17 and 21 more gradually. The first roller 17 moves toward the discharge end of the filter section while the other moves away from its associated roller 22 and toward the feed end of the filter. The net effect is to shorten the portion of the working run of the belt above the pans a given amount while simultaneously lengthening the portion of the working run below the pans the same amount. That is, the belt between rollers 17 and 30 becomes shorter while the length between rollers 21 and 22 increases.
In the usual operation, the second brake comprises the vacuum that holds the belt onto the drainage grids. However, if the unit is operated as a gravity filter without vacuum, then some other brake must be provided. In FIG. 13 this second brake has been designated 39. It can be located any place on the belt working run downstream of the second indexing roller 21 and upstream of the first indexing roller 17.
Because of the configuration of the belt system, the belt movements are quite complex and care must be taken to position the rollers correctly. For instance, upon indexing, some belt will actually move around the roller 17. In most cases this is required to satisfy the increased distance between the first indexing roller and the first fixed-position roller 20, such increase being the result of the indexing. Final positioning of the rollers will depend on the final configuration of the system but may be easily determined.
The belt is maintained under a nominal constant tension by the tension roller 29. This roller along with slidable bearings 37 and ram 38 can react to accommodate minor belt stretching or shrinking. The roller does not function as part of the belt indexing system.
A first brake is provided on the return run to selectively clamp the belt at a location between the first and second indexing rollers during rapid indexing of the carriage and belt; and a second brake is provided to clamp the belt in its return run during the active filtration cycle while the carriage is slowly retracted.
During the carriage retraction, a section of belt is slowly shifted downstream from the first indexing roller by virtue of the second indexing roller 21 moving away from the next roller 22 lengthening the return run. As the belt passes around the first roller 17 the cake carried thereon is discharged.
In order to provide functional separation of adjacent filtration steps a unique dam system is provided. This is illustrated in FIGS. 9 and 10. The dam 40 comprises an inflatable tube 41 carried in an inverted channel 42. As illustrated, the dam spans the belt transversely above the sidewalls of vacuum pans. As illustrated in FIG. 9, when the tube 41 is deflated for indexing, it is out of contact with the belt and cake. As shown in FIG. 10 the tube is inflated into contact with the cake during filtration thus functionally separating the cake from adjacent filtration functions. In some cases it may be desired to separate the cake into a plurality of zones above a single pan. This may be done with transverse dams not necessarily directly above the pan walls.
From the foregoing it is apparent that this invention is based on certain equipment requirements. The single carriage and the two indexing rollers mounted thereon are critical. This combination insures that each indexing is a duplicate of all other indexings and there is absolutely no need to separately shift and/or coordinate the two shiftable indexing rollers either on indexing or on resetting.
Since there are no driven rollers acting on the belt, belt wear by friction is substantially eliminated. The brake clamp does no damage because all it does is pinch the belt against the roller 20 during the brief indexing period, typically 5-7 seconds.
The system will utilize suitable controls, conveniently including a micro-processor to time and coordinate the various functions in accordance with the invention. Such controls are not described in detail because their function is well known.
Although the invention has been described in connection with vacuum filters, it has application to an enclosed filter operated as a pressure filter. Pans operated under vacuum are the equivalent of a pressure environment operated at a pressure differential. For gravity drainage the pressure differential can be imposed by the feed slurry. The filter section is in an "on" condition when a pressure differential is imposed. | A horizontal belt filter with incremental belt advance in which an endless belt is trained about a plurality of idler rollers to pass through an upper run which includes a filter section and a lower return run. The belt passes over only idler rollers. To index the belt for incremental advance through the filter section, a pair of idler rollers on a common shiftable frame are rapidly simultaneously shifted while the belt in the return run is braked against movement. The braking is accomplished by a pinch bar that presses against an idler roller with the belt between the bar and roller. After shifting, the belt is reset by slow retraction of the shiftable frame. All shifting of the frame is done by hydraulic rams. To assist in incremental belt advance, an air cushion may be introduced under the belt in the filter section. For feed distribution, and stage separation, inflatable dams are provided above the belt in the filtering section. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a drive system for a vehicle movable accessory, and especially a drive system for an automotive vehicle outer accessory, such as an antenna, a window glass, or a sun roof.
2. Description of the Prior Art
Japanese published unexamined utility model application 57-185205 discloses a control system for a motor driven rod antenna. In this control system, when the load on an antenna drive motor exceeds a certain level, the supply of an electric current to the motor is interrupted.
Japanese published unexamined utility model application 57-198104 discloses a drive system for a motor antenna mounted on a vehicle. In this drive system, an antenna drive motor is activated in response to a signal from an associated radio receiver power switch or a signal from a relay corresponding to the radio receiver power switch. The drive motor is deactivated in response to a signal from a switch of another sound device, a signal from a vehicle key switch, or signals from relays corresponding to the switch of the sound device and the key switch.
Japanese published examined utility model application 60-42487 discloses a power antenna including a antenna drive motor and limit switches. When an antenna reaches preset positions, these limit switches act to interrupt the electric current supply to the drive motor. This power antenna also includes a timer. In the case of a failure of the limit switches, the timer restricts the duration of the motor current supply to a preset interval.
Japanese published unexamined patent application 60-43903 discloses a motor antenna drive system. In this drive system, the position of an antenna is monitored by an angular position sensor associated with the shaft of an antenna drive motor. When the monitored position of the antenna reaches a given position, the drive motor is deactivated. The given position of the antenna can be selected from the longest position, the shortest position, and a position or positions intermediate between the two limit positions.
Japanese published unexamined patent application 61-18375 discloses a vehicle power window control system. In this control system, load on a window drive motor is monitored. In cases where the window is being closed, when the monitored motor load exceeds a reference level, the drive motor is stopped and is then reversed to open the window. After that, a device included in this control system inhibits activation of the drive motor in the direction of closing the window. The inhibitory operation of this device is cancelled by rethrowing a vehicular engine ignition switch.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a drive system for a vehicle movable accessory which enables reliable self-protection against undesirable locking or sticking of the accessory.
In a vehicle accessory drive system according to a first aspect of this invention, a rotatable motor is connected to a vehicle accessory to move the accessory. The accessory is movable between a first position and a second position. The motor moves the accessory toward the first position and the second position as the motor rotates in a first direction and a second direction respectively. A first operation signal is generated when the accessory is required to move toward the first position. A second operation signal is generated when the accessory is required to move toward the second position. Load on the motor is sensed. A stop signal is generated when the sensed motor load exceeds a reference level. The motor is stopped when the stop signal is generated. A device serves to rotate the motor in the first direction when the first operation signal is generated. A device serves to rotate the motor in the second direction when the second operation signal is generated. Rotation of the motor in the first direction is inhibited in response to the stop signal generated after generation of the first operation signal. The inhibition of rotation of the motor in the second direction is also cancelled in response to the stop signal.
In a vehicle accessory drive system according to a second aspect of this invention, a motor serves to move a vehicle movable accessory. When the accessory is required to move, the motor is activated. Load on the motor is sensed. When the sensed load exceeds a reference level, the motor is deactivated. After the motor is deactivated, a device inhibits activation of the motor which induces movement of the accessory in a direction which is the same as the direction of movement of the accessory during a period prior to the deactivation of the motor. The inhibition of activation of the motor is cancelled when the accessory is required to move in a direction different from the direction of movement of the accessory during the period prior to the deactivation of the motor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general block diagram of a vehicle accessory drive system according to an embodiment of this invention.
FIG. 2 is a specific block diagram of the vehicle accessory drive system of FIG. 1.
FIG. 3 is a diagram illustrating connection between contacts of a key switch of FIGS. 1 and 2 in four different positions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of this invention will be described hereinafter. In this embodiment, this invention is applied to a vehicle movable antenna. It should be noted that the invention is not limited to this embodiment and can be applied to other vehicle movable accessories such as a window and a sun roof.
With reference to FIG. 1, a key switch 10, a cassette switch 20, and a radio receiver switch 30 are connected in series. The key switch 10 is connected to an electric dc power source B such as a battery. The cassette switch 20 is actuated when a cassette tape is inserted into and removed from a cassette tape reproducing device or tape deck. The radio receiver switch 30 is connected to a radio receiver (not shown). The radio receiver is normally turned on and off in accordance with movement of the radio receiver switch 30. When the radio receiver switch 30 is actuated to turn on the radio receiver, the radio receiver switch 30 normally serves to generate an antenna extending signal. When the radio receiver switch 30 is actuated to turn off the radio receiver, the radio receiver switch 30 normally serves to generate an antenna shortening signal.
An up control circuit 40 is connected to the radio receiver switch 30 and a motor drive circuit 90. The motor drive circuit 90 is connected to an antenna drive motor M. The motor M is mechanically connected to an extensible or retractable radio receiver rod antenna described hereinafter. When the up control circuit 40 receives an antenna extending signal from the radio receiver switch 30, the circuit 40 outputs a normal rotation signal to the motor drive circuit 90, thereby rotating the motor M in its normal direction and extending the antenna. The up control circuit 40 outputs the normal rotation signal unless a stop signal, described hereinafter, is given.
A stop detection circuit 80 is connected to the up control circuit 40. The stop detection circuit 80 electrically monitors the load on the motor M. When the monitored motor load exceeds a reference level, the stop detection circuit 80 outputs a motor stop signal.
An up inhibition circuit 50 is connected to the radio receiver switch 30, the up control circuit 40, and the stop detection circuit 80. The up inhibition circuit 50 outputs a normal rotation inhibition signal to the up control circuit 40 in response to the stop signal from the stop detection circuit 80. The normal rotation inhibition signal is designed to prevent normal rotation of the motor M. The up inhibition circuit 50 holds the normal rotation inhibition signal until the previously-mentioned antenna shortening signal occurs. When the antenna shortening signal is outputted to the up inhibition circuit 50, the circuit 50 turns off the normal rotation inhibition signal.
A down control circuit 60 is connected to the radio receiver switch 30 and the motor drive circuit 90. When the down control circuit 60 receives an antenna shortening signal from the radio receiver switch 30, the circuit 60 outputs a reverse rotation signal to the motor drive circuit 90, thereby rotating the motor M in its reverse direction and shortening the antenna. The down control circuit 60 outputs the reverse rotation signal unless a stop signal outputted by the stop detection circuit 80 is given.
A down inhibition circuit 70 is connected to the radio receiver switch 30, the down control circuit 60, and the stop detection circuit 80. The down inhibition circuit 70 outputs a reverse rotation inhibition signal to the down control circuit 60 in response to the stop signal from the stop detection circuit 80. The reverse rotation inhibition signal is designed to prevent reverse rotation of the motor M. The down inhibition circuit 70 holds the reverse rotation inhibition signal until the previously-mentioned antenna extending signal occurs. When the antenna extending signal is outputted to the down inhibition circuit 70, the circuit 70 turns off the reverse rotation inhibition signal absent.
As shown in FIG. 2, the circuits 40, 50, 60, 70, 80, and 90 are continuously powered by the battery B independent of the states of the switches 10, 20, and 30.
The key switch 10 includes a movable contact +B and fixed contacts 10a, 10b, 10c, 10d, and 10e. The movable contact +B is connected to the positive terminal of the battery B. The fixed contact 10a is connected to a vehicular engine starting device (not shown). The fixed contacts 10b and 10c are connected to a vehicular engine ignition device (not shown). The fixed contact 10d is connected to vehicle accessories and a movable contact 20c of the cassette switch 20. The fixed contact 10e is generally isolated. As shown in FIG. 3, the key switch 10 is movable among an OFF position, an ACC position, an IG position, and an ST position. When the key switch 10 assumes the OFF position, the movable contact +B moves into connection with only the fixed contact 10e. When the key switch 10 assumes the ACC position, the movable contact +B moves into connection with only the fixed contact 10d, applying the voltage of the battery B to the vehicle accessories and the cassette switch 20. When the key switch 10 assumes the IG position, the movable contact +B moves into connnection with the fixed contacts 10b and 10c, applying the battery voltage to the engine ignition device, the vehicle accessories, and the cassette switch 20. When the key switch 10 assumes the ST position, the movable contact +B moves into connection with the fixed contacts 10a and 10b, applying the battery voltage to the engine starting device and the engine ignition device.
The cassette switch 20 includes fixed contacts 20a and 20b, and a movable contact 20c. As described previously, the movable contact 20c is connected to the fixed contact 10d of the key switch 10. When a cassette tape is inserted into the associated reproducing device, the movable contact 20c is connected to the fixed contact 20b but is disconnected from the fixed contact 20a. When a cassette tape is removed from the associated reproducing device, the movable contact 20c is connected to the fixed contact 20a but is disconnected from the fixed contact 20b. The fixed contact 20a is connected to the radio receiver switch 30. The fixed contact 20b is connected to the down control circuit 60 via a diode 122.
Provided that the key switch 10 is in the ACC position or the IG position, the radio receiver is turned on and off when the radio receiver switch 30 is closed and opened respectively. The radio receiver switch 30 is connected to the up control circuit 40 and the down inhibition circuit 70. The radio receiver switch 30 is also connected to the down control circuit 60 via a diode 121.
A main circuit 100 controlling the motor drive circuit 90 includes the up control circuit 40, the up inhibition circuit 50, the down control circuit 60, and the down inhibition circuit 70.
As described previously, the shaft of the motor M is mechanically connected to an extensible or retractable radio receiver rod antenna 110 via a known gear arrangement or drive train. When the shaft of the motor M rotates in a first direction and in a second direction, the antenna 110 is extended and shortened respectively.
The up control circuit 40 includes an OR gate 41, a differentiating circuit 42, a one-shot multivibrator 43, a flip-flop (FF) 44, and an AND gate 45. A first input terminal of the OR gate 41 is connected to the radio receiver switch 30. A second input terminal of the OR gate 41 is connected to an output terminal of an AND gate 54 within the up inhibition circuit 50. An output terminal of the OR gate 41 is connected to an input terminal of the differentiating circuit 42. The differentiating circuit 42 detects a rising edge of an output signal from the OR gate 41. An output terminal of the differentiating circuit 42 is connected to an input terminal of the one-shot multivibrator 43. The one-shot multivibrator 43 wave-shapes an output signal from the differentiating circuit 42 and outputs a set pulse having a fixed duration. An output terminal of the one-shot multivibrator 43 is connected to a set terminal of the flip-flop 44. A reset terminal of the flip-flop 44 is connected to the stop detection circuit 80 via an inverter 124. In the flip-flop 44, set operation takes precedence over reset operation. When the set terminal of the flip-flop 44 receives a high level signal from the one-shot multivibrator 43, the flip-flop 44 is set and generates a high level signal via its Q output terminal. When the reset terminal of the flip-flop 44 receives a stop signal from the stop detection circuit 80, the flip-flop 44 is reset and generates a low level signal via its Q output terminal. The Q output terminal of the flip-flop 44 is connected to a first input terminal of the AND gate 45. A second input terminal of the AND gate 45 is connected to the radio receiver switch 30. An output terminal of the AND gate is connected to the motor drive circuit 90.
The up inhibition circuit 50 includes a flip-flop 51, an AND gate 52, a flip-flop 53, and an AND gate 54. A set terminal of the flip-flop 51 is connected to the output terminal of the one-shot multivibrator 43 within the up control circuit 40. In the flip-flop 51, set operation takes precedence over reset operation. A first input terminal of the AND gate 52 is connected to the Q output terminal of the flip-flop 44 within the up control circuit 40. A second input terminal of the AND gate 52 is connected to the stop detection circuit 80 via the inverter 124. A set terminal of the flip-flop 53 is connected to an output terminal of the AND gate 52. In the flip-flop 53, set operation takes precedence over reset operation. A first input terminal of the AND gate 54 is connected to a Q output terminal of the flip-flop 53. A second input terminal of the AND gate 54 is connected to a Q output terminal of the flip-flop 51. As described previously, an output terminal of the AND gate 54 is connected to the OR gate 41 within the up control circuit 40. When the set terminal of the flip-flop 51 receives a high level signal from the one-shot multivibrator 43 within the up control circuit 40, the flip-flop 51 is set and generates a high level signal via its Q output terminal. When the set terminal of the flip-flop 53 receives a high level signal from the AND gate 52, the flip-flop 53 is set and generates a high level signal via its Q output terminal. The AND gate 52 is caused to output a high level signal by a stop signal from the stop detection circuit 80 and a signal outputted from the Q output terminal of the flip-flop 44 at a moment immediately prior to the moment of resetting of the flip-flop 44 by the stop signal. The AND gate 54 outputs a high level signal as a motor normal rotation inhibition signal when both of the flip-flops 51 and 53 are in their set states. Reset terminals of the flip-flops 51 and 53 are connected to an output terminal of an inverter 67 within the down control circuit 60. When the reset terminals of the flip-flops 51 and 53 receive a high level signal from the inverter 67, the flip-flops 51 and 53 are reset and remove or cancel the motor normal rotation inhibition signal.
The down control circuit 60 includes a delay circuit 61, an OR gate 62, a differentiating circuit 63, a one-shot multivibrator 64, a flip-flop 65, an AND gate 66, and the inverter 67. A first input terminal of the OR gate 62 is connected to the radio receiver switch 30 via the diode 121. The first input terminal of the OR gate 62 is also connected to the fixed contact 20b of the cassette switch 20 via the diode 122. A second input terminal of the OR gate 62 is connected to an output terminal of an AND gate 123. An inverting input terminal of the AND gate 123 is connected to the fixed contact 10c of the key switch 10. A non-inverting input terminal of the AND gate 123 is connected to the fixed contacts 10a and 10b. A third input terminal of the OR gate 62 is connected to an output terminal of an AND gate 74 within the down inhibition circuit 70. An input terminal of the delay circuit 61 is connected to an output terminal of the OR gate 62. An input terminal of the differentiating circuit 63 is connected to an output terminal of the delay circuit 61. The differentiating circuit 63 detects a falling edge of an output signal from the delay circuit 61. An input terminal of the one-shot multivibrator 64 is connected to an output terminal of the differentiating circuit 63. The one-shot multivibrator 64 wave-shapes an output signal from the differentiating circuit 63 and outputs a set pulse having a fixed duration. In the flip-flop 65, set operation takes precedence over reset operation. A set terminal of the flip-flop 65 is connected to an output terminal of the one-shot multivibrator 64. A reset terminal of the flip-flop 65 is connected to the stop detection circuit 80 via the inverter 124. A non-inverting input terminal of the AND gate 66 is connected to a Q output terminal of the flip-flop 65. An inverting input terminal of the AND gate 66 is connected to the output terminal of the OR gate 62. An output terminal of the AND gate 66 is connected to the motor drive circuit 90. An input terminal of the inverter 67 is connected to the output terminal of the OR gate 62. The device 67 inverts an output signal from the OR gate 62. When the set terminal of the flip-flop 65 receives a high level signal from the one-shot multivibrator 64, the flip-flop 65 is set and generates a high level signal via its Q output terminal. When the reset terminal of the flip-flop 65 receives a stop signal from the stop detection circuit 80, the flip-flop 65 is reset and generates a low level signal via its Q output terminal.
The down inhibition circuit 70 includes a flip-flop 71, an AND gate 72, a flip-flop 73, and an AND gate 74. A set terminal of the flip-flop 71 is connected to the output terminal of the one-shot multivibrator 64 within the down control circuit 60. A reset terminal of the flip-flop 71 is connected to the radio receiver switch 30. In the flip-flop 71, set operation takes precedence over reset operation. When the set terminal of the flip-flop 71 receives a high level signal from the one-shot multivibrator 64, the flip-flop 71 is set and generates a high level signal via its Q output terminal. A first input terminal of the AND gate 72 is connected to the Q output terminal of the flip-flop 65 within the down control circuit 60. A second input terminal of the AND gate 72 is connected to the stop detection circuit 80 via the inverter 124. The AND gate 72 is caused to output a high level signal by a stop signal from the stop detection circuit 80 and a signal outputted from the Q output terminal of the flip-flop 65 at a moment immediately prior to the moment of resetting of the flip-flop 65 by the stop signal. A set terminal of the flip-flop 73 is connected to an output terminal of the AND gate 72. A reset terminal of the flip-flop 73 is connected to the radio receiver switch 30. In the flip-flop 73, set operation takes precedence over reset operation. When the set terminal of the flip-flop 73 receives a high level signal from the AND gate 72, the flip-flop 73 is set and generates a high level signal via its Q output terminal. A first input terminal of the AND gate 74 is connected to the Q output terminal of the flip-flop 71. A second input terminal of the AND gate 74 is connected to the Q output terminal of the flip-flop 73. As described previously, an output terminal of the AND gate 74 is connected to the OR gate 62 within the down control circuit 60. The AND gate 74 outputs a high level signal as a motor reverse rotation inhibition signal when both of the flip-flops 71 and 73 are in their set states. When the reset terminals of the flip-flops 71 and 73 receive a high level signal from the radio receiver switch 30, the flip-flops 71 and 73 are reset and generate respective low level signals via their Q output terminals, removing or cancelling the reverse rotation inhibition signal outputted by the AND gate 74.
The motor drive circuit 90 includes a transistor 91, an electromagnetic winding or relay winding 92, a relay switch 93, a transistor 94, an electromagnetic winding or relay winding 95, and a relay switch 96. The base of the transistor 91 is connected to the output terminal of the AND gate 45 within the up control circuit 40. The emitter-collector path of the transistor 91 is connected across the battery B via the relay winding 92. When a high level signal is applied to the base of the transistor 91 from the AND gate 45, the transistor 91 is made conductive so that the relay winding 92 is energized by the battery B. When a low level signal is applied to the base of the transistor 91 from the AND gate 45, the transistor 91 is made non-conductive so that the relay winding 92 is de-energized. The relay switch 93 includes fixed contacts 93a and 93b, and a movable contact 93c. The fixed contact 93a is connected to the positive terminal of the battery B. The fixed contact 93b is connected to the stop detection circuit 80. The movable contact 93c is connected to a first terminal of the motor M. The relay switch 93 is associated with the relay winding 92. When the relay winding 92 is de-energized, the movable contact 93c is connected to the fixed contact 93b but is disconnected from the fixed contact 93a. When the relay winding 92 is energized, the movable contact 93c is connected to the fixed contact 93a but is disconnected from the fixed contact 93b so that an electric current produced by the battery B is generally allowed to flow through the motor M to rotate the motor M in its normal direction.
The base of the transistor 94 is connected to the output terminal of the AND gate 66 within the down control circuit 60. The emitter-collector path of the transistor 94 is connected across the battery B via the relay winding 95. When a high level signal is applied to the base of the transistor 94 from the AND gate 66, the transistor 94 is made conductive so that the relay winding 95 is energized by the battery B. When a low level signal is applied to the base of the transist or 94 from the AND gate 66, the transistor 94 is made non-conductive so that the relay winding 95 is de-energized. The relay switch 96 includes fixed contacts 96a and 96b, and a movable contact 96c. The fixed contact 96a is connected to the positive terminal of the battery B. The fixed contact 96b is connected to the stop detection circuit 80. The movable contact 96c is connected to a second terminal of the motor M. The relay switch 96 is associated with the relay winding 95. When the relay winding 95 is de-energized, the movable contact 96c is connected to the fixed contact 96b but is disconnected from the fixed contact 96a. When the relay winding 95 is energized, the movable contact 96c is connected to the fixed contact 96a but is disconnected from the fixed contact 96b so that an electric current produced by the battery B is generally allowed to flow through the motor M to rotate the motor M in its reverse direction.
The stop detection circuit 80 includes resistors 81, 82, 83, and 84, a comparator 85, a resistor 86, and a capacitor 87. A first end of the resistor 81 is connected to the fixed contacts 93b and 96b of the relay switches 93 and 96 within the motor drive circuit 90. The first end of the resistor 81 is also connected to a first input terminal of the comparator 85 via the resistor 86. A second end of the resistor 81 is connected to the negative terminal of the battery B via the ground. The resistor 81 senses load on the motor M. Specifically, an electric current flowing through the motor M passes through the resistor 81 so that the voltage across the resistor 81 represents the current flowing through the motor M. Since the current flowing through the motor M reflects the load on the motor M, the voltage across the resistor 81 represents the load on the motor M. The voltage across the resistor 81 will be called a motor load voltage hereinafter. The motor load voltage is applied to the first input terminal of the comparator 85. The resistors 82 and 83 are connected in series. The series combination of the resistors 82 and 83 is connected across the battery B. The junction between the resistors 82 and 83 is connected to a second input terminal of the comparator 85. The series combination of the resistors 82 and 83 divides the constant battery voltage and derives a reference constant voltage induced across the resistor 83. The reference constant voltage is applied to the second input terminal of the comparator 85. The reference constant voltage corresponds to a reference load on the motor M. When the motor load voltage is equal to or higher than the reference voltage, that is, when load on the motor M is equal to or greater than the reference load, the comparator 85 outputs a low level signal. When the motor load voltage is lower than the reference voltage, that is, when load on the motor M is smaller than the reference load, the comparator 85 outputs a high level signal. An output terminal of the comparator 85 is connected to an input terminal of the inverter 124. An output terminal of the inverter 124 is connected to the flip-flop 44 within the up control circuit 40, the AND gate 52 within the up inhibition circuit 50, the flip-flop 65 within the down control circuit 60, and the AND gate 72 within the down inhibition circuit 70. The comparator 85 is connected to the battery B so that the comparator 85 is powered by the battery B. The output terminal of the comparator 85 is connected to the positive terminal of the battery B via the resistor 84. Opposite ends of the capacitor 87 are connected to the first and second input terminals of the comparator 85 respectively.
During activation of the motor M, when the antenna 110 sticks or becomes locked due to some causes, the load on the motor M generally increases above the reference load so that the comparator 85 outputs a low level signal. This low level signal is converted by the inverter 124 into a high level stop signal. During activation of the motor M, when the antenna 110 is moving normally, the load on the motor M remains below the reference load so that the comparator 85 outputs a high level signal and thus a stop signal is absent.
When the key switch 10 is changed from the IG position to the ST position, the AND gate 123 outputs a high level signal to the down control circuit 60, thereby preventing the antenna 110 from being shortened. The high level signal outputted from the AND gate 123 to the down control circuit 60 also prevents the inhibition of antenna extending operation from being cancelled.
The vehicle accessory drive system of FIGS. 1-3 operates as follows.
[Up Operation]
In cases where the key switch 10 is in the ACC position or the IG position and where a cassette tape is removed from the cassete tape reproducing device so that the cassette switch movable contact 20c is connected to the cassette switch fixed contact 20a, when the radio receiver switch 30 is closed to turn on the radio receiver, an antenna extending signal consisting of a change from a low level to a high level is outputted via the radio receiver switch 30. In the up control circuit 40, an output signal of the OR gate 41 changes from a low level to a high level in response to the antenna extending signal, so that the differentiating circuit 42 outputs a pulse. This pulse from the differentiating circuit 42 is converted into a fixed duration pulse by the one-shot multivibrator 43. The fixed duration pulse from the one-shot multivibrator 43 sets the flip-flop 44 and the flip-flop 51 within the up inhibition circuit 50, so that high level signals are generated at the Q output terminals of these flip-flops 44 and 51. The high level signal from the flip-flop 44 allows the AND gate 45 to output a high level signal as a normal rotation signal, which makes the transistor 91 conductive. When the transistor 91 is made conductive, the relay winding 92 is energized so that the relay switch movable contact 93c is connected to the relay switch fixed contact 93a. The connection of the movable contact 93c to the fixed contact 93a allows the battery B to supply a normally directed electric current to the motor M, thereby rotating the motor M in its normal direction and extending the antenna 110.
[Suspension of Up Operation]
In cases where the motor M is rotated in its normal direction, when the antenna 110 is fully extended so that the motor M is locked, or when the antenna 110 sticks or becomes locked due to freezing or the like so that the motor M is locked, load on the motor M increases and thus the stop detection circuit 80 allows the inverter 124 to output a high level stop signal. This stop signal is applied to the reset terminal of the flip-flop 44, so that the flip-flop 44 is reset and the potential at the Q output terminal of the flip-flop 44 goes low. When the output signal from the flip-flop 44 goes low, the AND gate 45 is closed and thus the normal rotation signal from the AND gate 45 is made absent. As a result, the transistor 91 is made non-conductive and the relay winding 92 is de-energized. The de-energization of the relay winding 92 disconnects the relay switch movable contact 93c from the relay switch fixed contact 93a, thereby interrupting the electric current supply to the motor M and suspending the normal rotation of the motor M.
Immediately before the potential at the Q output terminal of the flip-flop 44 changes to a low level which causes the suspension of the normal rotation of the motor M, the stop signal outputted by the inverter 124 and the high level signal generated at the Q output terminal of the flip-flop 44 allow the AND gate 52 to output a pulse signal. The pulse signal from the AND gate 52 sets the flip-flop 53 so that a high level signal is generated at the Q output terminal of the flip-flop 53. Accordingly, the AND gate 54 receives the high level signals from the flip-flops 51 and 53, outputting a high level signal to the OR gate 41 as a normal rotation inhibition signal. The normal rotation inhibition signal lasts until the flip-flops 51 and 53 are reset.
During the presence of the normal rotation inhibition signal, even when an antenna extending high level signal is outputted via the radio receiver switch 30 again, the differentiating circuit 42 does not respond to the antenna extending signal so that the supply of a normally directed electric current to the motor M is prevented. Thus, in the case where the motor M is locked during or after the normal rotation, the supply of a normally directed electric current to the motor M is inhibited after the locking of the motor M. For example, an antenna extending high level signal is outputted again by rethrowing the key switch 10 while holding the radio receiver switch 30 closed. Also, an antenna extending high level signal is outputted again by actuating the cassette switch 20 while holding the radio receiver switch 30 closed.
[Down Operation]
In cases where the key switch 10 is in the ACC position or the IG position and where a cassette tape is removed from the cassette tape reproducing device so that the cassette switch movable contact 20c is connected to the cassette switch fixed contact 20a, when the radio receiver switch 30 is opened to turn off the radio receiver, an antenna shortening signal consisting of a change from a high level to a low level is outputted via the radio receiver switch 30. In the down control circuit 60, an output signal of the OR gate 62 changes from a high level to a low level in response to the antenna shortening signal. This change in the output signal from the OR gate 62 is transmitted to the differentiating circuit 63 via the delay circuit 61, so that the differentiating circuit 63 outputs a pulse. This pulse from the differentiating circuit 63 is converted into a fixed duration pulse by the one-shot multivibrator 64. The fixed duration pulse from the one-shot multivibrator 64 sets the flip-flop 65 and the flip-flop 71 within the down inhibition circuit 70, so that high level signals are generated at the Q output terminals of these flip-flops 65 and 71. The high level signal from the flip-flop 65 allows the AND gate 66 to output a high level signal as a reverse rotation signal, which makes the transistor 94 conductive. When the transistor 94 is made conductive, the relay winding 95 is energized so that the relay switch movable contact 96c is connected to the relay switch fixed contact 96a. The connection of the movable contact 96c to the fixed contact 96a allows the battery B to supply a reversely directed electric current to the motor M, thereby rotating the motor M in its reverse direction and shortening the antenna 110.
The antenna shortening signal is also transmitted to the reset terminals of the flip-flops 51 and 53 within the up inhibition circuit 50 via the OR gate 62 and the inverter 67, so that the flip-flops 51 and 53 are reset. When the flip-flops 51 and 53 are reset, the normal rotation inhibition signal outputted by the AND gate 54 is cancelled or removed.
[Suspension of Down Operation]
In cases where the motor M is rotated in its reverse direction, when the antenna 110 is fully shortened or retracted so that the motor M is locked, or when the antenna 110 sticks or becomes locked due to freezing or the like so that the motor M is locked, load on the motor M increases and thus the stop detection circuit 80 allows the inverter 124 to output a high level stop signal. This stop signal is applied to the reset terminal of the flip-flop 65, so that the flip-flop 65 is reset and the potential at the Q output terminal of the flip-flop 65 goes low. When the output signal from the flip-flop 65 goes low, the AND gate 66 is closed and thus the reverse rotation signal from the AND gate 66 is removed. As a result, the transistor 94 is made non-conductive and the relay winding 95 is de-energized. The de-energization of the relay winding 95 disconnects the relay switch movable contact 96c from the relay switch fixed contact 96a, thereby interrupting the electric current supply to the motor M and suspending the reverse rotation of the motor M.
Immediately before the potential at the Q output terminal of the flip-flop 65 changes to a low level which causes the suspension of the reverse rotation of the motor M, the stop signal outputted by the inverter 124 and the high level signal generated at the Q output terminal of the flip-flop 65 allow the AND gate 72 to output a pulse signal. The pulse signal from the AND gate 72 sets the flip-flop 73 so that a high level signal is generated at the Q output terminal of the flip-flop 73. Accordingly, the AND gate 74 receives the high level signals from the flip-flops 71 and 73, outputting a high level signal to the OR gate 62 as a reverse rotation inhibition signal. The reverse rotation inhibition signal lasts until the flip-flops 71 and 73 are reset.
During the presence of the reverse rotation inhibition signal, even when an antenna shortening signal is outputted again, the differentiating circuit 63 does not respond to the antenna shortening signal so that the supply of a reversely directed electric current to the motor M is prevented. Thus, in the case where the motor M is locked during or after the reverse rotation, the supply of a reversely directed electric current to the motor M is inhibited after the locking of the motor M.
The flip-flops 71 and 73 within the down inhibition circuit 70 are reset by a subsequent antenna extending signal outputted via the radio receiver switch 30. When the flip-flops 71 and 73 are reset, the reverse rotation inhibition signal outputted by the AND gate 74 is cancelled or removed. In the case where the reverse inhibition signal is absent, when the key switch 10 is moved to the OFF position, the down control circuit 60 and the motor drive circuit 90 allow a reversely directed electric current to flow through the motor M independent of the states of the cassette switch 20 and the radio receiver switch 30. This supply of the reversely directed current to the motor M continues until the antenna 110 is fully shortened or retracted.
As described previously, in cases where the antenna 110 is being extended or shortened, when the antenna 110 sticks or becomes locked due to freezing or the like, the activation of the motor M is suspended. Simultanesously, the up inhibition circuit 50 or the down inhibition circuit 70 generates a motor rotation inhibition signal which prevents or forbids the rotation of the motor M in the same direction as the direction of the rotation of the motor M during the period preceding the suspension of the activation of the motor M. This motor rotation inhibition signal lasts until a signal designed to rotate the motor M in the opposite direction is produced. In this way, after the antenna 110 sticks or becomes locked, the motor M is prevented from undergoing an electric current angularly forcing the motor M in the same direction as the direction of the rotation of the motor M during a period preceding the locking of the antenna 110. Accordingly, an abnormal or excessive electric current is prevented from flowing through the relay switches 93 and 96, so that long sevice lives of the switches 93 and 96 can be ensured.
To cancel the inhibition of the activation of the motor M, it is necessary to produce a signal designed to rotate the motor M in the direction opposite to the direction of the rotation of the motor M during a period preceding the locking of the antenna 110. Accordingly, in cases where the motor M is rotated in the same direction as the direction of the rotation of the motor M during a period preceding the locking of the antenna 110, the motor M needs to be rotated in the opposite direction before the motor M is rotated in the same direction as the direction of the rotation of the motor M during a period preceding the locking of the antenna 110. This rotation of the motor M in the opposite direction relieves stresses on the antenna 110 and the gear arrangement between the motor M and the antenna 110. Therefore, in cases where the motor M is rotated in the same direction as the direction of the rotation of the motor M during a period preceding the locking of the antenna 110 so that the motor M moves again into the same locked state, the motor M and the gear arrangement between the motor M and the antenna 110 are prevented from undergoing stronger stresses.
It should be noted that modifications may be made in the embodiment of FIGS. 1-3. For example, one of the up inhibition circuit 50 and the down inhibition circuit 70 may be omitted from the embodiment of FIGS. 1-3. In addition, a motor rotation inhibition signal outputted by the up inhibition circuit 50 or the down inhibition circuit 70 may be automatically removed or cancelled at a moment following the occurrence of the inhibition signal by a preset time interval determined by a device such as a timer. | A motor serves to move a vehicle movable accessory. When the accessory is required to move, the motor is activated. Load on the motor is sensed. When the sensed load exceeds a reference level, the motor is deactivated. After the motor is deactivated, a device inhibits activation of the motor which induces movement of the accessory in a direction same as a direction of movement of the accessory during a period preceding the deactivation of the motor. The inhibition of activation of the motor is cancelled when the accessory is required to move in a direction different from a direction of movement of the accessory during a period preceding the deactivation of the motor. | 4 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 60/760,669, filed Jan. 19, 2006 entitled A Method for Defective Pixel Detection Based on the Human Visual System.
BACKGROUND OF THE INVENTION
[0002] I. Field of the Invention
[0003] The present invention relates to the principals of image processing and, more specifically, to the detection and correction of pixels within a digital image having color values that may not have actually been in the original scene when the photo was taken. Such pixels are common due to dust particles or imperfections in CDD or CMOS photo array elements. In particular, the proposed method involves using lenient thresholds based on unperceivable differences by the human visual system to perform a quick-test of each pixel with its immediately surrounding neighbors. The present invention also relates to a bad pixel detection module and to program instructions executable by a processor for bad pixel detection.
[0004] II. Background
[0005] A defective image pixel is defined as a pixel whose response is considerably different than the value of its neighbors. Dust particles or microlens defects are two common reasons why a given pixel could report erroneous values.
[0006] A common method for bad pixel detection is to mark a given pixel as defective if it's response is some percentage or fixed threshold greater than the maximum, or some percentage or fixed threshold less than the minimum of it's neighbor's values. This process requires numerous read accesses from system memory followed by numerous logical comparisons to compute the maximum and minimum of each neighboring pixels neighbors.
[0007] There is a need to perform bad pixel detection at considerably faster speeds than current known methods. The speed at which bad pixel detection is performed can be optimized over prior methods by exploiting weaknesses in the human visual system. In short, more lenient thresholds can be used for the red color compared to thresholds green colors, and even more lenient threshold for blue color compared to red and green colors.
[0008] Furthermore, the red, green and blue thresholds can be further relaxed depending on the candidate pixel's magnitude.
SUMMARY OF THE INVENTION
[0009] In view of the above, it is an object of the present invention to provide a method for bad pixel detection at a considerably faster speed than current known methods.
[0010] A further object of the present invention is to provide a bad pixel detection scheme that performs a quick test on a pixel using a good neighbor pixel of the same color.
[0011] A further object of the present invention is to provide a bad pixel detection scheme that exploits weaknesses in the human visual system to optimize the speed of pixel detection.
[0012] A further object of the present invention is to provide a bad pixel detection scheme which employs more lenient thresholds for the red color pixels compared to thresholds of green color pixels, and even more lenient thresholds for blue color pixels compared to red and green color pixels.
[0013] A further object of the present invention is to provide a bad pixel detection scheme where the red, green and blue thresholds can be further relaxed depending on the candidate pixel's magnitude.
[0014] The foregoing and other objects of the present invention are carried out by a bad pixel detection module comprising a quick-test bad pixel detection sub-module operable to compare a difference between a pixel value of a current pixel in an image and a pixel value of only one good neighbor pixel to a threshold selected to create zero noticeable bad pixels in the image.
[0015] The bad pixel detection module further includes a full-test bad pixel detection sub-module operable to full-test the current pixel to evaluate whether the current pixel is a bad pixel in a kernel only if the current pixel fails the quick-test.
[0016] The present invention also provides a bad pixel detection module comprising a quick-test bad pixel detection sub-module which is operable to compare a difference between a current pixel value of a color in an image and one good neighbor pixel value of the color to a largest threshold. The largest threshold is based on a human visual system response to the color to create zero noticeable bad pixels in the image. The module also includes a full-test bad pixel detection sub-module which is operable to evaluate whether a noticeable bad pixel is a bad pixel in a kernel by a full-test of the kernel.
[0017] The bad pixel detection module further includes a quick-test bad pixel detection sub-module which is operable to compare the current pixel value to one and only one previously tested good neighbor. The quick-test repeats the quick-test for the next untested pixel.
[0018] The bad pixel detection module also includes a full-test bad pixel detection sub-module to resume testing of the current pixel when the current pixel is found to be a noticeable bad pixel during the quick-test.
[0019] The bad pixel detection module sets the thresholds for some pixel shades of the red color more lenient than the thresholds for the green color.
[0020] The bad pixel detection module sets the thresholds for each pixel shade of a blue color more lenient than the threshold for a red color and a green color. Moreover, as the magnitude of the pixel values increase, the threshold for the pixel values become more lenient.
[0021] In another aspect, the present invention is directed to program instructions executable by a processor, the program instructions upon execution being operable to quick-test a current pixel by comparing a difference between a pixel value of the current pixel in an image and a pixel value of only one good neighbor pixel to a threshold selected to create zero noticeable bad pixels in the image.
[0022] The program instructions upon execution being operable to full-test the current pixel to evaluate whether the current pixel is a bad pixel in a kernel only if the current pixel fails the quick-test.
[0023] In yet another aspect, the present invention is directed to a method for bad pixel detection comprising the steps of quick testing a current pixel by comparing a difference between a current pixel value of a color in an image and one good neighbor pixel value of the color to a threshold based on a human visual system response to the color to create zero noticeable bad pixels in the image, and full testing a noticeable bad pixel to evaluate whether the noticeable bad pixel is a bad pixel in a kernel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the accompanying drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangement shown. In the drawings:
[0025] FIG. 1 shows a common Bayer pattern arrangement;
[0026] FIGS. 2A , 2 B, and 2 C illustrate a pixel color scale of a single color from 0 to 255 shades dissected into hot, warm and cold pixel shade categories;
[0027] FIG. 3 illustrates a general block diagram of a bad pixel detection module interfaced with a bad pixel correction module shown in phantom;
[0028] FIG. 4 illustrates a block diagram of an image processing unit;
[0029] FIG. 5 illustrates a flowchart of a quick-test bad pixel detection method based on the human visual system; and
[0030] FIG. 6 illustrates a flowchart of an optimized quick-test bad pixel detection method based on the human visual system and optimized for RGB hot, warm and cold pixel shades.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] While this invention is susceptible of embodiments in many different forms, this specification and the accompanying drawings disclose only some forms as examples of the use of the invention. The invention is not intended to be limited to the embodiments so described, and the scope of the invention will be pointed out in the appended claims.
[0032] The preferred embodiment of the method and modules for defective pixel detection based on the human visual system according to the present invention is described below with a specific application to images for a liquid crystal display (LCD). However, it will be appreciated by those of ordinary skill in the art that the present invention is also well adapted for other types of display units using a RGB pixel scheme or other pixel colors for display. Referring now to the drawings in detail, wherein like numerals are used to indicate like elements throughout, there is shown in FIGS. 3 and 4 a module for bad pixel detection, generally designated at 10 , according to the present invention.
[0033] FIG. 1 shows a common Bayer pattern arrangement used by today's CCD or CMOS manufacturers. In this illustration, even rows contain alternating red and green pixels, and odd rows comprise alternating green and blue pixels. Herein, a pixel's “neighbors” is defined as adjacent pixels which are filtered to respond to the same portion of the color spectrum. For example, if checking to see if the red pixel denoted as R 33 is defective, the neighboring red pixels which may or may not be examined are those red pixels denoted R 11 , R 31 , R 51 , R 13 , R 53 , R 15 , R 35 , R 55 . When checking to see if the blue pixel denoted as B 44 is defective, neighboring blue pixels include those blue pixels denoted as B 22 , B 42 , B 62 , B 24 , B 64 , B 26 , B 46 , and B 66 . Finally, when examining a green pixel, e.g. G 43 , the green neighboring pixels are defined as those green pixel denoted as G 41 , G 32 , G 52 , G 23 , G 63 , G 34 , G 54 , and G 45 .
[0034] In the example, there are twice as many green pixels than there are blue or red pixels. The neighboring green pixels include those green pixels G 32 , G 52 , G 34 and G 54 which are at a distance of one (1) from the green pixel G 43 . The green pixels G 32 , 52 , G 34 and G 54 are corner green pixels immediately bordering the green pixel G 43 . The green pixels G 41 , G 23 , G 63 , and G 45 are at a distance of two (2) pixels from the green pixel G 43 . In this example, there are eight (8) red pixel neighbors, eight (8) blue pixel neighbors and eight (8) green pixel neighbors.
[0035] Since computing the maximum AND minimum of one's neighbors is a costly process, the bad pixel detection module 10 incorporates a quick-test bad pixel detection sub-module 20 which first compares the current or candidate pixel being processed to that of one of his neighbors already examined, in order to see if the two are within some threshold of which the difference would be unperceivable by the human visual system (HVS) 80 . If so, the bad pixel detection module 10 moves on to the next pixel for a quick-test bad pixel detection (hereinafter sometimes referred to as the “quick-test method”).
[0036] For example, if a given green pixel has a pixel value of 55, and has a upper-left green neighbor (already processed and known to be good) whose value is 65, then the pixel with the value 55 must either be good, or if it is in fact defective, it does not matter since the difference is too small to be detected by the HVS 80 .
[0037] The bad pixel detection module 10 further includes a full-test bad pixel detection sub-module 30 which performs a full-test bad pixel detection method (herein after referred to as a “full-test.”) In the exemplary embodiment, if the pixel under evaluation in the quick-test bad pixel detection sub-module 20 is found to be bad, then the bad pixel detection module 10 performs a full-test as will be described later. Nevertheless, if a pixel after the full-test is determined to be “bad” then the bad pixel is corrected by the bad pixel correction module 50 shown in phantom in FIG. 3 .
[0038] When the full-test is performed the current or candidate pixel is compared against all remaining neighboring pixels of the same color. In the exemplary embodiment, the quick-text bad pixel detection sub-module, always performs the quick-text on a current or candidate pixel using a good neighbor pixel located at the upper left of the current or candidate pixel. On the other hand, the full-test will test the current or candidate pixel with the remaining seven (7) neighboring pixels.
[0039] Referring now to FIG. 5 , the quick-test bad pixel detection method 100 will now be described in more detail. The method 100 begins with getting an untested pixel which is set as the current pixel at step S 102 . Step S 102 is followed by step S 104 where the current pixel value is compared to the good neighbor pixel value. The good neighbor pixel value is for a previously tested good neighbor of the same color. Step S 104 is followed by step S 106 where a determination is made whether the result (difference) of step S 104 is greater/less than the max/min human visual system threshold (HVS_TH). If the determination is “YES” (which indicates that the current pixel is good), then step S 106 is followed by step S 108 where a determination is made whether there are any more pixels not yet tested. If the determination at step S 108 is “YES,” step S 108 loops back or returns to step S 102 . Otherwise, if the determination is “NO,” at step S 108 , the method 100 ends.
[0040] Returning to step S 106 , if the determination is “NO” (which indicates that the current pixel is a noticeable bad pixel), then step S 106 is followed by step S 110 where a full-test for bad pixel detection is performed where the current pixel is tested against the remaining seven (7) neighboring pixels.
[0041] The quick-test method 100 can be optimized by using a more lenient threshold for red pixels, and even more lenient thresholds for blue Bayer pixels, since the human eye is least sensitive to changes at these frequencies. For example, tests have shown that a red, green, blue thresholds of 16, 12, 30, respectively, works well. The RGB thresholds 40 for the human visual system 80 are used by the quick-test bad pixel detection sub-module 20 .
[0042] The processing times are optimized in the bad pixel detection module 10 by utilizing the thresholds in hot, warm and cold lookup tables 42 A, 42 B and 42 C. The hot, warm and cold lookup tables 42 A, 42 B and 42 C include HVS thresholds for red, blue and green pixels based on whether the pixel value is hot, warm and cold. FIGS. 2A , 2 B, and 2 C illustrate a pixel color scale of a single color from 0 to 255 shades dissected into the hot, warm and cold shade categories, respectively. A pixel value (PV) of zero (0) represents the coldest pixel value. On the other hand, a pixel value of 255 represents the hottest pixel value. The pixel color scale from 0 to 255 may be for any single color such as red, green, blue, white, black, etc.
[0043] The boxes denoted as 230 , 240 in FIG. 2A , 130 , 140 in FIG. 2B and 30 , 40 in FIG. 2C correspond to pixel values 240, 230, 240, 130, 40, 30 in TABLES 1, 2 and 3 below. Each box includes approximately half of the pixel values between two adjacent shades of the same color. For example, box 30 includes pixel values from 26-35 or 25-34. On the other hand, the pixel values of box 40 includes the pixel values 36-45 or 35-44. Nevertheless, TABLES 1, 2, 3 may include an entry for each and every pixel value in the range of 0-255 or other scales of pixel shades. As will be seen from the TABLES 1, 2, and 3 below, the HVS threshold becomes more lenient as the pixel value magnitude increases.
[0044] These HVS thresholds for pixel values in the hot range are shown in Table 1 below.
[0000]
TABLE 1
PIXEL VALUE
(HOT RANGE)
190
200
210
220
230
240
250
RED_HVS
18
18
20
22
22
22
22
THRESHOLD
GREEN_HVS
18
18
18
20
20
20
20
THRESHOLD
BLUE_HVS
32
32
32
32
32
34
34
THRESHOLD
[0045] The HVS thresholds for pixel values in the warm range is shown in Table 2 below.
[0000]
TABLE 2
PIXEL VALUE
(WARM RANGE)
90
100
110
120
130
140
150
160
170
180
RED_HVS
16
16
16
16
16
16
16
16
16
16
THRESHOLD
GREEN_HVS
12
12
12
12
12
12
12
12
16
16
THRESHOLD
BLUE_HVS
32
30
30
30
30
30
30
30
32
32
THRESHOLD
[0046] The HVS thresholds for pixel values in the cold range is shown in Table 3 below.
[0000]
TABLE 3
PIXEL VALUE
(COLD RANGE)
10
20
30
40
50
60
70
80
RED_HVS
25
25
25
25
22
22
20
18
THRESHOLD
GREEN_HVS
25
25
20
20
20
18
16
16
THRESHOLD
BLUE_HVS
35
35
35
35
35
32
32
32
THRESHOLD
[0047] The red, blue and green HVS thresholds are used to define the maximum increase and decrease differences during the quick-test The result of the comparison between the current pixel value and the one good neighbor pixel value creates a difference between the two pixel values that is representative of either an increase or a decrease. The maximum pixel difference increase and the maximum pixel difference decrease for red pixels are denoted as MAX_PIX_DIFF_INC_R and MAX_PIX_DIFF_DEC_R. The maximum pixel difference increase and the maximum pixel difference decrease for a blue pixel is denoted as MAX_PIX_DIFF_INC_B and MAX_PIX_DIFF_DEC_B. The maximum pixel difference increase and the maximum pixel difference decrease for a green pixel is denoted as MAX_PIX_DIFF_INC_G and MAX_PIX_DIFF_DEC_G. For a pixel value of 120, which is a warm pixel value for red, green and blue pixels, the MAX_PIX_DIFF_INC_R is 16, the MAX_PIX_DIFF_INC_G is 12 and the MAX_PIX_DIFF_INC_B is 30. Likewise, for a pixel value of 120 for red, green and blue pixels, the MAX_PIX_DIFF_DEC_R is −16, the MAX_PIX_DIFF_DEC_G is −12 and the MAX_PIX_DIFF_DEC_B is −30.
[0048] The threshold values in TABLES 1, 2 and 3 above define the MAX_PIX_DIFF_INC and MAX_PIX_DIFF_DEC (which is the negative of the threshold value in the TABLES 1, 2 and 3).
[0049] Referring now to FIG. 6 , the optimized quick-test bad pixel detection method 200 will now be described in detail. The method 200 begins with getting an untested pixel which is set as the current pixel at step S 202 . Step S 202 is followed by step S 204 where the pixel value for the one good neighbor pixel (GNP) is obtained. In the example, the upper-left good neighbor pixel is used as a reference point. Step S 204 is followed by one of the steps S 206 A, 206 B, and 206 C to determine whether the GNP pixel is red, blue or green, respectively. If the GNP pixel is red, then step S 206 A is followed by steps 208 A where the red HVS threshold for the corresponding pixel value of the GNP is obtained from the hot, warm and cold lookup tables 42 A, 42 B and 42 C.
[0050] For example, if the GNP is red and has a pixel value of 30, the red HVS threshold is 25 (see TABLE 3). Step S 208 A is followed by step S 210 A where the max/min HVS threshold (HVS TH) is set to the red HVS threshold from the hot, warm and cold lookup tables 42 A, 42 B and 42 C.
[0051] If the GNP pixel is blue as determined at step S 206 B, then step S 206 B is followed by steps 208 B where the blue HVS threshold for the corresponding pixel value is obtained from the hot, warm and cold lookup tables 42 a, 42 b and 42 c. For example, if the GNP is blue) and has a pixel value of 230, the blue HVS threshold is 32 (see TABLE 1). Step S 208 B is followed by step S 210 B where the max/min HVS threshold (HVS TH) is set to the blue HVS threshold from the hot, warm and cold lookup tables 42 A, 42 B and 42 C.
[0052] If the GNP is green as determined at step S 206 C, then step S 206 C is followed by steps 208 C where the green HVS threshold for the corresponding pixel value is obtained from the hot, warm and cold lookup tables 42 a, 42 b and 42 c. For example, if the GNP is green and has a pixel value of 40, the green HVS threshold is 20 (see TABLE 3). Step S 208 C is followed by step S 210 C where the max/min HVS threshold (HVS TH) is set to the green HVS threshold from the hot, warm and cold lookup tables 42 A, 42 B and 42 C.
[0053] The RGB HVS thresholds in TABLES 1, 2 and 3 are selected such that zero noticeable false negatives are produced.
[0054] Steps S 210 A, 210 B, and 210 C are followed by step S 212 where the current pixel value (red, blue or green) is compared to one good neighbor pixel value. Step S 212 is followed by step S 214 where a determination is made whether the result (difference) of step S 212 is greater/less than the max/min human visual system threshold (HVS TH) from one of steps S 210 A, 210 B, and 210 C. As can be appreciated, the comparison step S 212 can be moved to begin immediately after step S 204 .
[0055] When determining whether the result is greater/less than the HVS TH, the determination evaluates whether the result is less than the MAX_PIX_DIFF_INC or whether the result is greater than the MAX_PIX_DIFF_DEC. If the determination is “YES” (which means the current pixel is good or not noticeable), then step S 214 is followed by step S 216 where a determination is made whether there are any more pixels not yet tested. If the determination at step S 216 is “YES,” step S 216 loops back or returns to step S 202 where the next untested pixel is evaluated. Otherwise, if the determination is “NO,” at step S 216 , the method 200 ends.
[0056] Returning to step S 214 , if the determination is “NO” (which means the current pixel is bad or noticeable) then step S 214 is followed by step S 218 where a full-test for bad pixel detection is performed by the full-test bad pixel detection sub-module 30 .
[0057] Referring now to FIG. 4 . the image processing unit 60 includes an Advanced RISC Machine (ARM) 65 or other processing device which is coupled to program instructions 70 and display 75 , such as without limitation, a liquid crystal display (LCD). The ARM 65 is coupled to an image source 55 providing an image of pixels subjected to image processing by the image processing unit 60 . The program instructions 70 upon execution by the ARM 65 are operable to function as the bad pixel detection module 10 and the bad pixel correction module 50 . Thus, the program instructions 70 , upon execution, are operable to perform the quick-test and the full-test for bad pixel detection.
[0058] In operation, exploiting the HVS 80 to minimize the need to compute the min and max of each pixel's neighbors helped speed up bad pixel correction on the Advanced RISC Machine (ARM) 2.6 times faster.
[0059] It will be appreciated by those of ordinary skill in the art that by the module, method and program instructions disclosed herein, the detection of bad pixels is accomplished considerably faster than in the conventional art. The speed at which bad pixel detection is performed can be optimized over prior methods by exploiting weaknesses in the human visual system. The process for defective pixel detection according to the present invention is also more economical than the conventional process, for example, which requires computation of maximum and minimum of neighboring pixel values.
[0060] The foregoing description of the embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents. | A bad pixel detection method and module which provide a quick-test and a full-test for bad pixel detections in an image. The quick-test tests a current pixel to one and only one good neighbor having been previously tested. The quick-test is optimized by exploiting weaknesses in the human visual system especially for red and blue colors. More lenient thresholds can be used for the blue color compared to thresholds for the red and green colors. Moreover, the full-test is constructed and arranged to detect bad pixel clusters in a kernel. | 7 |
This application claims the benefit of priority of U.S. provisional application Ser. No. 61/752,885 filed on Jan. 15, 2013.
FIELD OF THE INVENTION
The field of the invention is regasification of liquid natural gas (LNG).
BACKGROUND
The following description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
Natural gas is a common fuel source that has many important applications. Natural gas is often transported in its liquid form, referred to herein as liquid natural gas (LNG), since it takes up much less volume. Upon arriving at its destination near a source of use (e.g., power plant) the LNG can be converted back into a gaseous state via a regasification process.
Numerous regasification devices, systems, and processes are known. For example, Conversion Gas Imports, L.P. (“CGI”) is the owner of the following U.S. Patents related to regasification: U.S. Pat. Nos. 5,511,905; 6,739,140; 6,813,893; 6,880,348; 6,848,502, 6,945,055, 7,036,325. These and all other referenced extrinsic materials are incorporated herein by reference in their entirety. Where a definition or use of a term in a reference that is incorporated by reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein is deemed to be controlling.
Some of the patents listed above describe designs for a LNG receiving terminal using salt cavern storage. The LNG may come directly from a ship or from a conventional storage tank. The LNG receiving terminal may be located onshore or offshore.
Some of these patents also describe methods for warming LNG and storage in compensated or uncompensated salt caverns, which is referred to as the Bishop Process™.
Some of the patents listed above also describe pipe-in-pipe heat exchanger designs. One embodiment of the LNG receiving terminal uses multiple salt caverns for blending of gas from different sources to achieve a pipeline standard BTU (i.e., British Thermal Units) content.
Unfortunately, current regasification technology suffers from numerous drawbacks. For example, some of the patents listed above describe systems in which a warming fluid (e.g., seawater) is discharged into the sea after use. The discharged fluid can have a negative impact on the environment (e.g., the discharged seawater is often too cold and can kill fish eggs, thus reducing the population of sea life).
The company GTherm has recently conceived of a new approach for power generation that relies on geothermal wells (see FIG. 1 ). The GTherm approach utilizes a closed-loop system and a circulating fluid. The circulating fluid is heated as it passes through a geothermal well and cools as it passes through an evaporator. GTherm has also conceived of applying similar principles to enhanced oil recovery systems. However, to the best of applicant's knowledge, those of ordinary skill in the art have failed to provide a closed-loop system with a circulating fluid that utilizes heat from geothermal wells for LNG regasification systems.
US20070079617 describes methods and systems for geothermal vaporization of liquefied natural gas. However, the system described in US20070079617 does not appear to provide a pipe-in-pipe heat exchanger to efficiently utilize heat from geothermal wells.
Thus, there remains a need for improved systems and methods for LNG regasification.
SUMMARY OF THE INVENTION
The inventive subject matter provides apparatus, systems, and methods for the warming of cold fluids, such as liquefied natural gas (LNG), using the heat from a geothermal energy heat source (e.g., geothermal well). In one aspect of some embodiments, a warming fluid (e.g., water, oil, brine, etc.) is circulated in a closed-loop system that passes through or near a geothermal energy heat source and then passes through a heat exchanger. As the warming fluid passes near the geothermal energy heat source, heat is transferred to the warming fluid. The warming fluid then passes through a heat exchanger where the warming fluid transfers heat to a liquid natural gas stream. The heat transferred from the warming fluid to the LNG stream helps to convert the LNG stream from a liquid state to a gaseous state as the LNG stream passes through the heat exchanger. The warming fluid is then circulated back to the geothermal energy heat source to repeat the process.
In one aspect of some embodiments, the heat exchanger comprises a pipe-in-pipe configuration, in which the LNG stream passes through an inner pipe and the warming fluid passes through an annular space around the exterior of the inner pipe. A portion of the length of the inner pipe has a bulkhead for stress and thermal expansion containment between cold LNG (upstream) and warm gas (downstream). The warming fluid crosses over the bulkhead section of the inner pipe via a bypass conduit (e.g., cross over piping).
Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic of a power generation process that utilizes geothermal energy.
FIG. 2 is a schematic of a pipe-in-pipe LNG regasification system that utilizes geothermal energy.
FIG. 3 is a perspective cross-sectional view of the pipe-in-pipe heat exchanger shown in FIG. 2 .
FIG. 4 is a side cross-sectional view of the pipe-in-pipe heat exchanger shown in FIG. 2 .
FIG. 5 is an exploded view of the pipe-in-pipe bulkhead configuration shown in FIG. 2 .
FIGS. 6 a and 6 b are perspective and cross-sectional views, respectively, of one embodiment of a geothermal well for use in a regasification system.
FIG. 7 is a perspective view of the geothermal well of FIG. 6 a with an optional vacuum insulated tubing.
FIGS. 8 a and 8 b are perspective and cross-sectional views, respectively, of a geothermal well with a grout tube for installing thermal grout.
FIGS. 9 a and 9 b are perspective and cross-sectional views, respectively, of another embodiment of a geothermal well for use in a regasification system.
FIGS. 10 a -10 e are various views of another embodiment of a geothermal well for use in a regasification system.
DETAILED DESCRIPTION
The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
The inventive subject matter provides apparatus, systems, and methods for the regasification of liquid natural gas (LNG) using geothermal energy.
FIG. 2 shows a general configuration and piping diagram for a LNG closed-loop regasification system 100 . System 100 has a closed-loop conduit (e.g., fluid pathway) with a warming fluid 105 circulating therein. A pump 130 creates a negative pressure in the closed-loop conduit, causing the circulating fluid 105 to circulate through the geothermal well 110 and the heat exchanger 120 , and through distribution piping 132 . (Shut off and control valves, leak detection and controls instrumentation are not shown for clarity.) When passing through the geothermal well 110 , the circulating fluid 105 is heated. The heat 111 is transferred to the LNG 140 flowing through the pipe-in-pipe heat exchanger 120 , causing the LNG 140 to change from a liquid state to a gaseous state (e.g., natural gas 150 ). Distance 122 is the distance to turn LNG into natural gas and is dependent upon the heat transfer required.
The warming fluid 105 (also referred to as the circulating fluid) can be water, oil, brine, or any other fluid suitable for transferring heat under the required specifications. In some embodiments, the circulating fluid has a high heat capacity so that it retains heat over long distances and/or time.
Pipe 170 carriers LNG 140 from a LNG source to heat exchanger 120 . FIG. 3 shows a cross-sectional view of a pipe 170 . Pipe 170 comprises a cryogenic rated inner pipe 171 surrounded by an insulation material 172 (e.g., aerogel insulation, a suitable commercially-available example of which includes NANOGEL® EXPANSION PACK™, available from CABOT). Surrounding insulation material 172 is an external carbon steel casing pipe 173 , however, another cryogenic rated pipe could be used if so required. Around pipe 173 is a concrete weight coating 174 , if required. Various pipe configurations for transporting LNG are known and may be used with the inventive principles presented herein unless stated otherwise in the claims.
FIG. 4 shows a side cross-sectional view of the pipe-in-pipe heat exchanger 120 . Warming fluid 105 enters exchanger 120 at point 401 at a high temperature. Fluid 105 transfers heat to LNG 140 as it flows along distance 122 (fluid 105 flows in the inner pipe and warming fluid 105 flows in the annular space between the outer and inner pipe). Fluid 105 exits exchanger 120 at point 402 at a lower temperature than it was at point 401 . Heat exchanger 120 has a bulkhead 125 , which provides stress and thermal expansion containment as LNG 140 converts to natural gas 150 . Fluid 105 crosses over bulkhead 125 via cross over piping 126 .
FIG. 5 shows an exploded view of pipe bulkhead 125 . Bulkhead 125 helps provide integrity to handle stress and thermal expansion containment between the cold LNG entering heat exchanger 120 and the warm natural gas (i.e., gaseous state) exiting heat exchanger 120 . In some embodiments, the configuration of bulkhead 125 can be similar in principle to the pipe-in-pipe bulkhead described in WO2005119150, which is incorporated herein by reference. As illustrated in FIGS. 2, 4 and 5 , the bulkhead 125 may be characterized as a tube having two longitudinal ends and a body portion between the first end and the second end that form two conical portions, the two conical portions converging at the smallest diameter of the respective conical portion, the body portion thereby having a longitudinal v-shaped cross sectional area.
FIGS. 6 a and 6 b are perspective and cross-sectional views, respectively, of one embodiment of a geothermal well heat exchanger 600 . The heat exchanger 600 comprises a pipe 616 that has an open hole 620 partially filled with thermal grout 640 . Heat exchanger 600 is disposed within a geothermal region 670 . The heat exchanger 600 also includes a u-shaped conduit (e.g., pipe) disposed within pipe 616 for circulating a fluid 610 into and out of the well (via inlet piping 612 and outlet piping 614 ). The u-shaped pipe is part of a closed-loop system 605 such as is shown in FIG. 2 , and has at least one welded connection 650 at the elbow and at least one joint/weld 630 (e.g., screwed drill collar). Thermal grout 640 facilitates the transfer of heat 660 from geothermal region 670 to the warming fluid 610 . The exact configuration (e.g., size, dimension, shape, materials, temperatures) of the conduit will vary depending on the application. FIG. 6 b provides examples of diameters, weights, materials, and specifications, which are not intended to limit the application of the inventive concepts described herein. In this particular embodiment, pipe 616 is casing pipe that has a 30 inch outer diameter (OD) and 1 inch width, and inlet 612 and outlet 614 have a 4 inch inner diameter and 2 inch width.
FIG. 7 shows a perspective view of an alternative embodiment 700 of the geothermal well 600 of FIG. 6 a , with an optional vacuum insulated tubing 780 near the top end of the well.
FIGS. 8 a and 8 b are perspective and cross-sectional views, respectively, of the geothermal well 600 of FIG. 6 with a removable grout tube 885 in the center of the well and a spacer 890 for installing thermal grout in the bottom end of the well.
FIGS. 9 a and 9 b are perspective and cross-sectional views, respectively, of another embodiment of a heat exchanger 900 in a geothermal well for use in a regasification system. The well comprises a cased hole 916 grouted in place and a vacuum insulated tubing 980 in the center. The circulating fluid 910 flows into the geothermal well through the cased hole 912 (e.g., annular space) and out of the center vacuum tubing 980 (via the open bottom of return line/pipe 914 ). Spacers and centralizers 990 keep return line/pipe 914 centered.
FIGS. 10 a -10 b show various views of an alternative embodiment 1000 of heat exchanger 900 in a geothermal well for use in a regasification system. The well comprises a center vacuum insulated tube 1012 with an open end near the bottom of the well. The well also includes an outer casing 1016 surrounded by thermal grout 1040 . The circulating fluid 1010 flows into the well via the center tube 1012 and out of the well via the casing 1016 (e.g., annular space 1014 ).
FIG. 10 c shows a heat exchanger 1110 what has a manifold 1115 at the top end of the well. The manifold 1115 brings the casing 1116 outer diameter space into one smaller diameter tubing 1114 . A granular insulation can be used around the exterior surface of the manifold and within the casing. Heat exchanger 1110 has a center pipe 1112 that provides an inlet.
FIGS. 10 d and 10 e show cross sectional views near the top end and bottom end, respectively, of the geothermal well.
Grout 111 , developed by Brookhaven National Laboratories specifically for geothermal applications, is one example of a grout that can be used with geothermal wells. Unlike other grouting materials, Grout 111 is virtually water impermeable, is shrink resistant, is crack resistant, and boasts the highest known heat conductivity of any other known grout in existence.
A newer grout, called Mix 111 , can also be used. Mix 111 is composed of cement, water, silica sand and small amounts of super plasticizer and bentonite. The formula for Mix 111 has been publically provided by Brookhaven National Laboratories.
By utilizing this material, and grouting from the bottom up, a total seal around the well is provided. This both protects the tubing and provides a safe sealant to prevent the cross-contamination of underground aquifers at varying depths.
The systems and methods described herein are useful for a LNG import situation where there is a need for a regasification system from a LNG tanker at a berth, where the LNG can be converted in the pipeline running from the shop to shore and an onshore natural gas grid. The systems and methods described herein can also be used for heat-upon-demand applications.
In addition, the systems and methods described herein can also be used for a re-gas system for a LNG plant where LNG is stored over time and natural gas is needed to enter a pipeline grid (e.g., a peak shaving plant). The systems and methods could be used in a LPG (liquefied petroleum gas) system as well, although the temperatures are lower.
Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.
Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the scope of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. | Regasification systems and processes for converting liquid natural gas (LNG) from a liquid into a gaseous state are described. The process includes a closed-loop system that uses geothermal wells as a heat source. A warming fluid circulates through the closed-loop system coupled with a geothermal well and a LNG heat exchanger. The warming fluid is heated as it passes through the geothermal well and cooled as it passes through the LNG heat exchanger, thus heating and gasifying the LNG. The cooled warming fluid then returns to the geothermal well. The closed-loop system minimizing environmental impact by eliminating the need to discharge the warming fluid. | 5 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to a digital display device and, particularly, to a micro-electrical-mechanical system (MEMS) digital display device.
[0003] 2. Description of Related Art
[0004] Recently, seven-segment displays are widely used in digital clocks, electronic meters, and other electronic devices for displaying alphanumeric information.
[0005] In a typical digital display device, light emitting diode (LED) based seven-segment displays are commonly used. However, each LED requires packaging before application, thus it makes the digital display device large and heavy, which is not suitable for the miniaturized handheld devices for displaying alphanumeric information.
[0006] Therefore, a new digital display device is desired to overcome the above mentioned problems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Many aspects of the embodiments can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0008] FIG. 1 is a schematic, perspective view of a digital display device in accordance with a first embodiment of the present invention.
[0009] FIG. 2 is a schematic, top plan view of a reflective member group of FIG. 1 .
[0010] FIG. 3 is a schematic, perspective view of a reflective member of FIG. 2 .
[0011] FIG. 4 is a schematic, perspective view of a moving mirror in the reflective member of FIG. 3 .
[0012] FIG. 5 is a schematic, top plan view of a reflective member group in accordance with a second embodiment of the present invention.
[0013] FIG. 6 is a schematic, top plan view of a reflective member group in accordance with a third embodiment of the present invention.
DETAILED DESCRIPTION
[0014] Embodiments will now be described in detail below with reference to the drawings.
[0015] Referring to FIG. 1 , a digital display device 100 includes a light source 10 , a converging member 20 , a MEMS chip 30 , and a projection member 40 .
[0016] The light source 10 can be one of a laser source and a light emitting diode (LED) source.
[0017] The converging member 20 includes two converging lenses 22 , 24 for converging light emitted from the light source 10 onto the MEMS chip 30 .
[0018] The MEMS chip 30 reflects the light transmitted from the converging member 20 to form an alphanumeric character. The alphanumeric character can be ten Arabic numerals, Latin letters, Cyrillic, Greek alphabets or mathematical symbols.
[0019] The projection member 40 includes two projection lenses 42 , 44 . The projection member 40 projects the alphanumeric character onto a projection screen 50 .
[0020] The MEMS chip 30 is fabricated using MEMS and complementary metal oxide semiconductor (CMOS) techniques. The MEMS chip 30 includes a substrate 32 , a light absorption layer 34 formed on the substrate 32 , and a plurality of reflective member groups 36 formed on the light absorption layer 34 , and a controller 38 . The substrate 32 can be a silicon substrate, for example. In one embodiment, the light absorption layer 34 can be made of chromium. Because the light absorption layer 34 not covered by the reflective member groups 36 can absorb light, the projection screen 50 appears dark corresponding to the light absorption layer 34 not covered by the reflective member groups 36 . Each reflective member group 36 consists of a plurality of reflective members arranged in a predetermined pattern being configured for displaying one of the alphanumeric characters. In the present embodiment, four reflective member groups 36 are adopted. It can be understood that the number of the reflective member groups 36 depends on the application and requirements. The controller 38 can be a pulse-width modulation (PWM) controller.
[0021] Referring to FIGS. 2-3 , each reflective member group 36 consists of seven reflective members 362 arranged in a seven-segment pattern. Each reflective member 362 includes a mirror 3622 , two torsion beams 3624 , two support posts 3626 , a first electrode 3627 , a second electrode 3628 , and two insulation pads 3629 . In the seven-segment pattern, seven mirrors 3622 are arranged as a rectangle of two vertical mirrors 3622 on each side with one horizontal mirror 3622 on the top and bottom, respectively. Additionally, the seventh mirror 3622 bisects the rectangle horizontally.
[0022] The mirror 3622 suspends above the light absorption layer 34 . The mirror 3622 is strip shaped. The mirror 3622 includes a first side edge 3622 a , a second side edge 3622 b , and two opposite ends 3622 c , 3622 d . The mirror 3622 is made of polysilicon. The mirror 3622 can further have a metal layer (not shown), such as gold or copper layer formed thereon to enhance the reflective effect thereof.
[0023] The two torsion beams 3624 extend from opposite ends 3622 c , 3622 d of the mirror 3622 respectively. The two torsion beams 3624 are fixed to the mirror 3622 by an adhesive or solder. It can be understood that the torsion beams 3624 can also be integrally formed with the mirror 3622 . Each of the torsion beams 3624 is made of elastic polysilicon and is deformable.
[0024] The two support posts 3626 connect the two torsion beams 3624 , respectively, in order to support the two torsion beams 3624 and the mirror 3622 .
[0025] Each of the insulation pads 3629 is disposed between each of the support posts 3626 and the light absorption layer 34 . Each of the insulation pads 3629 is made of silicon nitride or silicon dioxide.
[0026] The first electrodes 3627 and the second electrodes 3628 are disposed on the light absorption layer 34 below the first and the second side edges 3622 a , 3622 b of the mirror 3622 , respectively.
[0027] Referring to FIG. 4 , when a voltage is applied to the first electrode 3627 and the mirror 3622 , the mirror 3622 moves relative to the light absorption layer 34 with the first side edge 3622 a towards the first electrode 3627 due to an electrostatic attraction between the first electrode 3627 and the mirror 3622 . The mirror 3622 can return to its original position when the voltage is withdrawn. Likewise, when a voltage is applied to the second electrode 3628 , the mirror 3622 moves relative to the light absorption layer 34 with the second side edge 3622 b towards the second electrode 3628 . The controller 38 of the MEMS chip 30 can control the voltage applied to the first electrode 3627 or the second electrode 3628 . In the present embodiment, the reflective member 362 is in the first position when the mirror 3622 moves towards the first electrode 3627 , while the reflective member 362 is in the second position when the mirror 3622 moves towards the second electrode 3628 . When the mirror 3622 is in the first position, light from the converging member 20 is reflected onto the projection screen 50 . When the mirror 3622 is in the second position, light is directed elsewhere, usually onto a heatsink (not shown) for example. The mirrors 3622 in the first positions cooperatively form an alphanumeric character. It can be understood that the reflective member 362 can be in the first position when the mirror 3622 moves towards the second electrode 3628 , which can be controlled by adjusting the optical path. Therefore, to reposition each mirror 3622 of each reflective member 36 , light incident upon the MEMS chip 30 can be selectively reflected into the projection member 40 , thus resulting in the corresponding alphanumeric character being displayed on the projection screen 50 . Each of the moving angles between the first electrode 3627 and second electrode 3628 and the mirror 3622 are the same. The moving angles can be a predetermined value, for example 10-12 degrees.
[0028] Referring to FIG. 5 , a reflective member group 60 according to a second embodiment is shown. The reflective member group 60 consists of fourteen reflective members 362 arranged in a fourteen-segment pattern. It is an extension of the above described reflective member group 36 in the first embodiment, but adding four diagonal mirrors 3622 and two vertical mirrors 3622 and with two middle horizontal mirrors 3622 other than one.
[0029] Referring to FIG. 6 , a reflective member group 70 according to a third embodiment is shown. The reflective member group 70 consists of sixteen reflective members 362 arranged in a sixteen-segment pattern. It is an extension of the above described reflective member group 60 in the second embodiment, but with two horizontal mirrors 3622 on the top and bottom, respectively.
[0030] It can be understood that the layout and the number of the mirrors in each reflective member group are not limited to the above described embodiments, which can be set according to the alphanumeric character being displayed.
[0031] The digital display device 100 is fabricated using MEMS and CMOS techniques, thus the digital display device 100 is compact, light-weight, low cost, and very suitable for the miniaturized handheld device, for example, mp3, cell phone, for displaying the alphanumeric information.
[0032] While certain embodiments have been described and exemplified above, various other embodiments from the foregoing disclosure will be apparent to those skilled in the art. The present invention is not limited to the particular embodiments described and exemplified but is capable of considerable variation and modification without departure from the scope and spirit of the appended claims. | An exemplary digital display device includes a light source, a converging member, a micro-electrical-mechanical system (MEMS) chip, and a projection member. The converging member is for converging the light emitted from the light source onto the MEMS chip. The MEMS chip is for selectively reflecting light transmitted from the converging member to form an alphanumeric character to the projection member. The projection member is for projecting the alphanumeric character onto a projection screen. | 6 |
FIELD OF THE INVENTION
[0001] The present invention is related to a method for the prevention and possibly the treatment of chronic diseases, preferably inflammatory associated chronic diseases that may affect an animal including a man (human), by the administration of a sufficient amount of a (functional) food or feed to the diet of this animal.
[0002] Inflammation is a complex biological response of vascular tissues to an harmful stimulus. Inflammations which run unchecked could lead to a host of diseases, especially acute or chronic diseases, such as hay fever, atherosclerosis and rheumatoid arthritis that are not down-regulated by the body.
[0003] In chronically inflamed tissues, a stimulus is persistent and therefore, a recruitment of monocytes is maintained. Existing macrophages are maintained in place and proliferation of these macrophages is stimulated.
[0004] Immune system is also often involved with inflammatory disorders demonstrated in both allergic reaction and in some myopathies. Furthermore, non-immune diseases with etiological origin in inflammatory process include cancer, atherosclerosis and ischemic heart (Ischemia) disease. Other disorders with inflammation include asthma, auto-immune diseases, chronic inflammation, chronic prostatitis, glomerulonephritis, per sensitivities, inflammatory bowel disease, pelvic inflammatory disease, reperfusion injury, rheumatoid arthritis, transplant rejection and vasculitis. An allergic reaction formerly known as type 1 hyper sensitivity also the result of an inappropriate immune response triggering inflammation. Other hyper sensitivity reactions (type 2 and type 3) are mediated by antibody reactions and induces inflammation by attracting leukocytes, which damage surrounding tissue. Inflammatory myopathies are caused by the immune system inappropriately attacking component of muscle leading to site of muscle inflammation. They may occur in conjunction with other immune disorders such as systemic sclerosis and including dermatomyositis, polymyositis and inclusion body myositis. It is also known that high level of several inflammations relating markers such as IL-6, IL-8 and TNF-alpha are associated with obesity. During clinical study, inflammatory related molecule levels were reduced and increased levels of anti inflammatory molecules were detected within 4 weeks after patient began a very low caloric diet. Furthermore, the association of systemic inflammation with insulin resistance and atherosclerosis has been also the subject of intensive research.
[0005] Prolonged inflammation, known as acute or chronic inflammation leads to a progressive shift of the type of cells which are present at the site of inflammation and is characterized by simultaneous destruction and healing of the tissue from the inflammatory process that could lead to chronic diseases, such as obesity, diabetes mellitus, cardio- and cerebrovascular diseases like hypertension or ischemia, auto-immune diseases (including diseases of inflammatory origin like arthritis or lupus), brain diseases (including neuro-degenerative diseases like Alzheimer disease, Parkinson disease, Huntington disease, multiple sclerosis, depression or schizophrenia), asthma, systemic sclerosis, allergies and cancer.
[0006] Therefore, in the present description, the applicant will use for the same effect, the words “chronic inflammation”, “chronic inflammation associated disease” or “inflammatory disorders” that constitute a large and related group of disorders which underlies a variety of human diseases.
[0007] Cholesterol in the animal kingdom has been submitted to an evolutionary selective process, yet it sits and functions in animal cells for hundreds of million years. In the 6-million-year-old hominid species, cholesterol accounts for 70 g per 70 kg body weight (0.1% w:w) and is distributed over all organs and tissues through blood circulation.
[0008] Cholesterol has been evolutionary selected as a unique blood and tissue active component in animals evolving in a wild environment. In such a land-based environment, body fats in herbivorous animals are characterized by a ˜1:1 ratio between the two plant essential fatty acids (EFAs), linoleic acid (LA, C18:2ω6) and alpha-linolenic acid (ALA, C18:3ω3).
[0009] It exists a need especially in the animal population for a reduction of these chronic diseases by a modification of the diet of animals preferably in mammals including the diet of humans.
[0010] These modifications should lead to a reduction of cholesterol-related chronic diseases for improving the health of animals, especially mammals subjects including human patients and for reducing the development of chronic diseases especially chronic inflammation and chronic inflammation associated diseases or disorders.
[0011] Verschuren et al. indicated that factor other than cholesterol, but diet-related are important for the prevention of heart disease (Serum total cholesterol and long-term coronary heart disease mortality in different cultures. Twenty-five-year follow-up of the seven countries study JAMA 1995; 274: 131-136). Moreover, the inventors previously demonstrated that the diets the study of Verschuren have very different ω6 & ω3 contents.
SUMMARY OF THE INVENTION
[0012] The present invention is related to the use of (or to a method of prevention and possibly treatment) which comprises the step of adding to the diet of an animal) a sufficient amount of a (functional) natural (i.e. non genetically modified) food or feed composition inducing in total blood, serum, plasma or yolk of an animal, an HUFAs ω6 of about 25% (with a variance of about 5%) for the manufacture of a medicament to be administrated to this animal for an efficient prevention and possibly an efficient treatment of chronic diseases especially chronic inflammatory associated diseases affecting this animal, being preferably a mammal, including a human.
[0013] A functional and natural food or feed composition means a composition present in the diet of an animal, preferably a mammal, including a human, which is made of natural ingredients (non genetically modified ingredients obtained from non genetically modified plants or animals). Such restriction to natural compound is preferred, because national and European authorities do not accept a presence of genetically modified organisms or their portion in a composition destinated to domestic animals or humans. This percentage should be limited to 0.9% according to the European authorities.
[0014] Furthermore, it exists also an important discussion in human population regarding the drawbacks of genetically modified ingredients, especially genetically modified plants.
[0015] The food or feed composition according to the invention may comprise different ingredients of animal, vegetal or mineral (salt) origin.
[0016] Therefore, in the present invention, it is not possible to define the characteristic of the specific composition according to the invention, because it could be made of different ingredients having different ratios of (ω6 and ω3 polyunsaturated) fatty acids, but the mixture of these different ingredients will allow the preparation of a composition which is suitable for the diet of an animal, preferably a mammal, including a human, to induce in total blood, serum, plasma or yolk of the animal an HUFAs ω6% of about 25%, with a possible variance of 5%.
[0017] However, if the ingredients of such food or feed composition are of animal origin, they have preferably a ratio of ω6:ω3 polyunsaturated fatty acids PUFAs=1:1 with a variance of about 10%, preferably with a variance of about 5%. Examples of such ingredients of animal origin are egg, milk, meat, blood, skin, fat, fish, shell fish or a mixture thereof.
[0018] However, an ingredient comprising a higher concentration of ω3 polyunsaturated fatty acids may be added in order to obtain an efficient balance of ω6 and ω3 fatty acids in the composition.
[0019] The ingredients of the composition according to the invention could be also of a vegetable origin and may have preferably a ratio of ω6:ω3 essential fatty acids EFAs=1:3 with a variance of about 10%, preferably with a variance of about 5%.
[0020] Advantageously, these ingredients of vegetable origin are preferably selected from the group consisting of oils, vegetables roots or seeds possibly present in various compositions of vegetable origin, such as bread, paste or cookies. The composition may further comprise also suitable amount of carbohydrates, amino-acids (or proteins), anti-oxidants, vitamins and minerals (salt).
[0021] According to the invention, the inflammatory associated chronic diseases (inflammatory chronic disease or a disease of inflammatory origin) affecting this animal, preferably a mammal, including a human, are selected from the group consisting of obesity, diabetes mellitus, cardio- and cerebro-vascular diseases (atherosclerosis, hypertension, Ischemia) auto-immune diseases (including diseases of inflammatory origin, such as lateral Amyotrophic sclerosis, arthritis or lupus), brain diseases (including neurodegenerative diseases, such as Alzheimer disease, Parkinson disease, Huntington's disease, multiple sclerosis, depression or schizophrenia), asthma, systemic sclerosis, allergies and cancer.
[0022] Another aspect of the present invention is related to a method for the preparation of the functional and natural food or feed composition according to the invention which comprises ingredients of animal and/or vegetable origin. This method comprises the step of
identifying the percentage of fatty acids in each usual ingredient present in the recipe of the composition, and modifying the recipe of this composition by mixing one or more of these usual ingredients with one or more additional ingredient(s) of animal or vegetable origin to obtain a composition inducing HUFAs ω6 of about 25% (with a variance of about 5%) in total blood, serum, plasma or yolk of an animal preferably by comprising a composition of animal HUFAs ω6 of 25% (with a variance of about 10% or 5%) and of vegetable EFAs ω6 of 25% (with a variance of about 10% or 5%).
DETAILED DESCRIPTION OF THE INVENTION
[0025] Essential fatty acids (EFAs; linoleic acid, LA, C18:2 ω6 and α-linolenic acid ALA, C18:3 ω3) are from vegetable or animal origin, while highly unsaturated fatty acids (HUFAs) are derived by an animal from EFAs (PUFA is the sum of EPA and HUFA).
[0026] The inventors have identified unexpectedly that an advantageous 25% ω6 in blood total, serum, plasma or yolk. HUFAs (%ω6 HUFAs=25) is equivalent to the 1:1 into in serum PUFAs (ω6:ω3-PUFAs=1:1) in an animal, preferably a mammal, including an human and that this equivalence depends neither upon the type of diet (vegans, vegetarians, omnivorous, fish- or meat-based), neither upon the species (human, others mammals or birds), nor upon the latitude on earth where they live and dwell (Poles, Temperate Zones, Tropical and Sub-Tropical Zones, Equator, East, West, Continental).
[0027] Therefore, it seems that there is an universal rule among biological species on earth that define this percentage of ω6-HUFAs=25 and/or ω6:ω3-PUFAs=1:1 as an ideal blood and/or serum/yolk environment for moderate, cause-effect proportionate, healthy tissue-inflammatory responses to take place. Deviating from that gene-compliant standard may lead to chronic inflammation and associated diseases on the long run.
[0028] The inventors have identified that the proportion of ω6 in blood total highly unsaturated fatty acids (%ω6-HUFAs) is an accurate index of these tissues pro-inflammatory state, on the one hand, of dietary intake of polyunsaturated fatty acids (PUFAs), on the other hand and to the potentialization of the harmful effect of blood cholesterol. 25% ω6 in blood total HUFAs appears as an ideal diet-derived safeguard against these tissues inflammations and development of the mentioned chronic diseases.
[0029] Within diet comprising essential fatty acids, ratios are important, not amounts. Essential fatty acids (EFAs) are linoleic acid (LA C18:2 ω6) and alpha-linolenic acid (ALA, C18:3 ω3). It is now known that no more than 1% of daily intake energy (DEI) is needed as LA. Provided that threshold amount is reached, then a 1:3 ratio of LA:ALA is all what it takes to reach 25% ω6-HUFAs in total blood lipids and, as far as this dietary ω6:ω3-EFAs=1:3 ratio is maintained, an increase in the daily intake of LA will have no effect on the blood proportion of ω6 in total HUFAs. As there appears to be no absolute requirement for ω3-HUFAs (and therefore game and fish) in the human's diet, a vegan or a vegetarian diet can be perfectly fine with regards to human needs.
[0030] However, one must realise that today's modern food environment, loaded with hidden omega-6 fatty acids (LA, AA) does require the omnipresence of compensating ω3-HUFAs. This notion of ratios rather than the amount is of importance from a geographic perspective. Human populations live under different latitudes where sunshine and fats are differently distributed. For instance, cold polar environments favour HUFAs and EFAs, rainy temperatured latitudes favour EFAs and MUFAs (mono unsaturated fatty acids), and sunny tropical and equatorial latitudes favour MUFAs and SAFAs (saturated fatty acids). In wild-type environments under these different latitudes, ancient diets provide PUFAs that favour this preferred 25% ω6-HUFAs in total blood lipid and/or the ω6:ω3-PUFAs=1:1 in total serum lipids. However, ω6-rich grains and grain-fed livestock, thus not cholesterol and saturated fats, appear as the most single identified health care concern in modern man's diet around the world, including that of modern Inuits, Japanese, and Mediterranean. Moreover, those who were the least exposed to dietary PUFAs (Mediterranean zones and below) are also those who are at the highest risk of developing chronic diseases (and also obesity) when fed with ω6 rich modern foods, since this regimen is comparatively poor in ω3, needed to restore the ideal ratio.
[0031] Furthermore, the inventors have discovered that when applied to modern livestock (poultry), a balanced ratio of essential fatty acids (ω6:ω3 EFAs or PUFAs=1:1) in the animal (bird) body fat translates unexpectedly into a ˜1:3 ratio of ω6 to ω3 in its blood (and yolk of the obtained egg) highly unsaturated fatty acids (ω6:ω3 HUFAs=1:3).
[0032] It appears that Nature has selected cholesterol as an ideal tissue active component for land-based herbivorous animals complying with the following rules in terms of body fat and blood (yolk) fatty acid distribution (see table 1). Concurrently, such body fat and blood (yolk) fatty acid composition, when associated with the right diet-derived balance of essential amino acids, antioxidant vitamins and minerals, must be ideal for circulating lipoproteins (blood cholesterol) and tissue health & homeostasis, in land-based herbivorous animal species.
CHD-Mortality and HUFAs in Man: Epidemiological Studies
[0033] Human prospective epidemiological evidence tends to show that the proportion of ω6 in blood total HUFAs is a potentially accurate parameter to estimate the risk of developing chronic diseases (Non-communicable diseases or NCDs), including obesity, diabetes mellitus, cardiovascular disease (CVD), hypertension, stroke, and some type of cancers, that are multigenic and multifactorial), such as exemplified by WEM Lands for coronary heart disease (CHD), and that the preferred proportion of 25% ω6 in blood total HUFAs (ω6:ω3 HUFAs=1:3) is an ideal epidemiologically-derived diet-related make-up in terms of protection against onset and development of such chronic diseases.
[0034] It is remarkable that the epidemiologically-determined safest blood HUFAs composition in man (25% ω6 HUFAs or ω6:ω3 HUFAs=1:3) is consistent with that naturally established in wild land-based herbivorous animals, and that the latter naturally establishes itself in modern livestock raised on a wild-type plan diet.
From Nutrition Facts to Nurturing Facts
[0035] Epidemiological evidence tends to support the view that Classic Nutrition Facts could be advantageously substituted for Modern Nurturing Facts to show essential rather than the non-essential fat content of the food (see table 2). Saturated and mono-unsaturated fats as well as cholesterol are non-essential for man. Saturated fats and cholesterol are secondary risk factors for chronic human diseases, whereas essential and highly unsaturated fatty acids determine body tissue composition, health and homeostasis.
[0036] The contribution of balanced Egg such as described in the European Patent EP128236781 to blood total ω6 HUFAs is calculated from an empirical equation derived by WEM Lands that is available on the US NIH website: http://efaeducation.nih.gov/sig/dietbalance.html and/or at http://www.sbsoft.be/columbus-concept-5.html
[0037] The mathematical model can be used to accurately test a diet or to approximately test a specific food item for its potential contribution to HUFA-related tissue inflammatory status and, in turn, to evaluate the potential risk of developing a chronic disease by keeping on such a diet for a long time or by eating such food item on a regular basis (Table 3).
[0038] This interactive learning website can also be used to help determine a potentially ideal dietary essential fatty acid distribution that is needed to maintain tissue health and homeostasis. In particular, linoleic acid (LA, C18:2 ω6) must be taken into consideration here since saturation of fatty acid physiological pathways leading to endogenous synthesis of eicosanoids (autacoids) in rat and man appears to require less than 1.0% of D.E.I. (22.22 Cal or 2.5 gm) as LA. Intakes in excess of that threshold seem to lead to impairment of ω3-HUFAs synthesis and accretion in tissues and organs. Computational analysis of US NIH website equation leads to an optimized dietary ratio of plant fats, ie ω6:ω3-EFAs=1:3 (25% ω6-EFA/75% ω3-EFA) which maintains a proportion of 25% ω6 in blood total HUFAs. Interestingly, this distribution of essential fats is typical of ubiquitous greens and ancient seeds, such as flax, chia and perilla, on which man and wild-land based herbivorous animals have evolved.
[0039] ω6-rich grain-extracted table oils were not part of the food chain until Modern Agriculture came into play. From the classification obtained in table 3, it appears that most table oils seem to contribute to tissue inflammation and the onset of chronic diseases, so they could not have supported man's inception. Only certain Olive Oil (low in linoleic acid), Columbus Oil (described in the Patent Application WO2005/020698 and which is a corrected olive oil), chia, flax and perilla oils tends to composition that is compatible with man's tissue homeostasis. Modern meat obtained from livestock fed ω6-rich grains is also inflammatory, because of its high content of animal-derived ω6-HUFAs.
[0040] Among suitable functional food or feed composition to be used in the present invention, the person skilled in the art may select ocean fatty fishes or food or feed composition comprising them that are balancing foods in a modern type diet. Thanks to their high content in ω3-HUFAs, they can help in reducing the pro-inflammatory properties of modern oils & fats, and meats.
[0041] Very important is the fact that dairy products—including full fat milk, butter and cream—are low in essential fatty acids and do not contribute to HUFA-related tissue inflammation, yet they may contribute to increases in the classic TC:HDL and LDL:HDL ratios because of their saturated fatty acids content. However, the person skilled in the art may also obtain wild-type milk that present substantially lowered ratios of medium to long chain fatty acids (MCFA: −25%; LCFA: +25%). Therefore, wild-type dairies all belong to a healthy balanced diet where total fat and energy are kept under control.
[0042] Last but not least, the person skilled in the art should also take into consideration published and current recommendations for the use of fatty acid composition ((a) Simopoulos A P et al., Essentially of and recommended dietary intakes for ω-6 and ω-3 fatty acids. Food Rev International 2000; 16:113-117; (b) Scientific Committee on Food. Report on the Revision of Essential Requirements of Infant Formulae and Follow-on Formulae. SCF/CS/NUT/IF/65 Final (18 May 2003), EU Commission, Health & Consumer Protection Directorate General).
[0043] Genetically speaking, human beings have not changed over the 10,000 years since the development of modern agriculture. Healthy human beings exhibit balanced body fats (ω6:ω3-EFAs=1:1) and/or a low proportion of ω6 in blood total HUFAs (ω6 in HUFAs=25%). These compositions can be obtained and maintained through selection of land-based wild-type diets, complying with the same ratios when from animal origin (game, river fish) and in favour of omega-3 fatty acids (ω6:ω3-EFAs=1:3) when from plant origin (leafy vegetables, some seeds & nuts).
[0000]
TABLE 1
Hen's body
Yolk total
Fatty acid (%)
fat
lipids
C16:0
12.90
19.34
C18:0
5.43
9.18
C16:1ω7
2.34
3.17
C18:1ω9
33.92
37.74
C18:2ω6
21.16
13.59
C18:3ω3
21.16
11.69
C20:4ω6
0.04
0.81
C20:5ω3
0.03
0.28
C22:5ω3
0.02
0.43
C22:6ω3
0.04
1.86
ω6:ω3 EFAs
~1:1
—
ω6:ω3 HUFAs
—
~1:3
ω6:ω3 PUFAs
~1:1
~1:1
[0000]
TABLE 2
CE: Columbus Egg (One 65-g egg);
D.E.I.: daily energy intake,
RDI: recommended daily intake
[0000]
TABLE 3
Traditional foods as per their predicted potential contribution
to tissue inflammation and development of chronic diseases
Blood
%
%
% ω6
% ω3
% ω6
Predicted
Oils & fats
LA
ALA
HUFAs
HUFAs
HUFAs
Risk
Sunflower oil
61
0.1
—
—
76
+++
Grapeseed oil
68
0.5
—
—
76
+++
Corn oil
51
1.0
—
—
74
+++
Peanut oil
35
0.1
—
—
73
+++
Wheat germ oil
55
7
—
—
70
+++
Soybean oil
54
7.5
—
—
70
+++
FAO/WHO
11.1
0.92
0.74
0.37
70
+++
1994
Walnut oil
62
12
—
—
68
+++
Olive oil (1)
13
0.6
—
—
63
++
Palm oil
9
0.25
—
—
58
++
Canola oil
20
10
—
—
54
++
Std egg
17.03
0.66
2.03
1.17
50
+
Std red meat
22.60
2.66
3.70
1.21
49
+
Std white meat
20.64
2.20
5.83
2.26
46
+
Olive oil (2)
5
0.6
—
—
47
+
Columbus oil
7
7
—
—
38
0
Col red meat
24.73
21.36
1.96
3.04
32
0
Col white meat
22.02
15.07
4.40
6.68
30
0
Columbus egg
13.59
11.69
0.81
2.57
27
0
Coconut oil
1.5
0.1
—
—
25
0
Chia oil
19
64
—
—
24
0
Flax oil
15
57.5
—
—
22
0
Greek egg
6.10
2.63
2.67
4.10
22
0
Salmon
5.20
5.30
9.80
28.80
20
0
Perilla oil
12.6
63.2
—
—
18
−
Trout
5.50
6.00
4. 30
21.20
12
−
Full fat milk
3.5
1.0
—
—
11
−
Mackerel
1.28
0.07
0.37
18.84
2
−−
Atlantic herring
0.78
0.04
0.27
7.20
2
−−
Pacific herring
0.67
0.07
—
8.11
1
−−
[0044] “Predicted HUFA-related Risk” (correlated here to the contribution of the food to %ω6 in blood total HUFAs) is calculated from US NTH website http://efaeducation.nih.gov/sig/dietbalance1.html for an intake of 20 g edible oil, 100-g edible egg (8.4 g total fatty acids), meat & fish (4.75 g total fatty acids), and milk (3.8 g total fatty acids) when contributing to a 30% fat-containing diet (2,222 Cal). Fatty acid compositional data are from The Lipid Handbook (Gunstone F D, Harwood L L & Padley F B, 2 nd Ed), Chapman & Hall, 1994, ISBN 0 412 43320 6. Data on Chia oil are retrieved from www.eatchia.com Greek Ampelistra egg is from Simopouios A P & Salem H Jr. N-3 fatty acids in eggs from range-fed Greek chickens. N Engl J Med 1989; 321:1412 (letter). FAO/WHO 1994 were recommended standards for infant formula; here computing was made for <1 yr of age infant fed 900 ml milk formula daily. “Col” stands here for Columbus. | The present invention is related to a method for the prevention and possibly the treatment of chronic diseases, preferably inflammatory associated chronic diseases that may affect an animal including a human, by the administration of a sufficient amount of a (functional) food or feed to the diet of this animal. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention has to do with an apparatus for the generation of pressure amplification suitable for use in projecting a projectile. A controlled chemical reaction is sustained by precisely controlling the power applied to a fuel delivering plasma generator in communication with a source of oxidizer fluid. Upon reaction of the fuel and the oxidizer, or simply the oxidation of the plasma, pressure in the reaction chamber is dramatically increased resulting in sufficient pressure to power a projectile at significant velocity.
2. Description of the Prior Art
This invention draws from the combined technology of liquid propellant propulsion technology and electrothermal propulsion technology neither of which teach this hybrid combination.
In liquid propellant technology one or more fluids can be combined to generate a chemical reaction that produces pressure to power a projectile. The metering and mixing of the two fluids is difficult to control and therefore is subject to the risk of catastrophic failure or at least erratic performance. Usually mechanical means require seal and metering technology which is unreliable and so expensive as to be unjustifiable in a high production environment.
The electrothermal propulsion system is a new technology that utilizes the electrical output of an inductive or capacitive network which condenses a pulse from an electrical generating source and energizes the cathode of the system. Dielectric breakdown plasma is directed to a chamber containing an inert working fluid which is vaporized to provide gas pressure to eject or propel a projectile. All of the projectile energy is derived from the electrical power pulse. The resulting device has the serious drawback of being extremely bulky due to the excessive size of the electrical power supply which makes the unit difficult to integrate with desirable platforms for use as projectile launchers.
SUMMARY OF THE INVENTION
The propulsion or pressure amplification system disclosed herein is a hybrid unit combining the liquid propellant and the electrothermal technologies resulting in an efficient propulsion unit that has ameliorated the disadvantages of those technologies. The instant invention is a combustion augmented plasma (CAP) device that uses a plasma cartridge to controllably inject fuel into an oxidizer chamber. The plasma cartridge functions as an electric feed pump whose injection rate is controlled by the power applied to the plasma cartridge. The chemical reaction of the oxidizer with fuel supplied by the plasma feed pump provides the principal source of energy for generation or amplification of pressure. The uses of such generated pressure are several such as the production of an impact force or the generation of a controlled pressure increase for use in propelling a projectile.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of this invention incorporates the use of the pressure amplification property in a gun system (hereinafter "CAP gun"). Such a system is shown in the drawing FIGURE wherein a projectile, its host cartridge and a gun chamber and barrel environment are shown in a section view and indicated generally by 10.
In the FIGURE the cartridge receiver 12 is aligned in a conventional manner with the gun barrel 14. The receiver 12 includes a first counterbore 16 providing a cartridge stop ledge 20 that locates the cartridge 24 in the receiver chamber 12. The bore of the receiver chamber extends to ledge 22 which defines the inner end of the barrel portion 14. The cartridge 24 is comprised of an outer metallic housing having a first chamber containing a dielectric retaining shoulder 32. The dielectric extends from an end portion 42 extending outwardly from the outer metallic housing to a point at an innermost end 34 of the dielectric where the metallic housing has an inwardly extending projection 52.
A capillary 36 is provided in the dielectric which extends through the dielectric and provides a storage location for another dielectric, hereinafter the first dielectric, 44 as well as a first conductive means 46. The first conductive means 46 can be an anode or cathode and in a preferred embodiment is a cathode connected to an electrical power source (not shown) which in a preferred embodiment is a pulse forming network (PFN) of a conventional type. The inner end portion of the first conductive means 46 is provided with the enlarged head portion providing a shoulder 50 that contacts the dielectric 26 and prevents the first conductive means 46 from being forced out the end of the cartridge in the same way that the dielectric 26 is restrained in the outer metallic housing 24 by means of the dielectric retaining shoulder 32. The capillary 36 inboard of the end of the first conductive means 46 extends from the first conductive means 46 to and through the inwardly extending projection 52 of the metallic housing whereby an orifice or a gate means is formed by and in the inwardly extending projection. The innermost end of the capillary 36 is sealed with a membrane 54. This membrane prevents contamination from reaching the first dielectric 44 in the capillary 36.
The first chamber of the cartridge or fuel chamber thereof is a plasma generator when supplied with electrical energy from the first conductive means to the inwardly extending projection of the cartridge which is a second conductive means.
A second chamber of the cartridge is an oxidizer containing chamber or a fluid containing chamber containing energetic fluid, that is, a fluid capable of releasing energy, and being a source thereof. The energetic fluid is, in a preferred embodiment, an oxidizer means oxidizer material 56 which would be in direct communication with the first dielectric if not for the membrane 54. The energetic fluid will release its energy when it reacts with a plasma gas as explained further on.
A projectile 60 will be positioned in the barrel portion of gun and typically would abut a sealed end of the oxidizer containing chamber. Alternative embodiments are contemplated where the projectile is integral with the cartridge. The operation of the CAP gun system is initiated after loading the gun with the live cartridge and the projectile. In a preferred embodiment outer metallic housing 24, or second conductive means, is used as an anode and the first conductive means 46 is a cathode. The first dielectric 44 is a polyethylene material providing a first resistance contained in the capillary 36 between the inboard end of the first conductive means and the membrane 54. The capillary is formed in a second or additional dielectric also of polyethylene. This additional dielectric is concentrically configured inside the outer metallic housing thereby providing the capillary as shown in the drawing figure.
Although a long chain hydrocarbon polymer such as polyethylene is a preferred dielectric many electrically insulating, solid, combustible, organic or inorganic materials suit this purpose.
The oxidizer means 56 in this preferred embodiment is 70% hydrogen peroxide (H 2 O 2 ) and is contained between the membrane 54 and the projectile 60. If the projectile is separate from the cartridge then a membrane will be provided to seal the end of the cartridge.
The pulse forming network (PFN), which is the power supply, is designed such that it can produce sufficient energy, in a small plasma generator on the order of 10-100 Kilovolts, to bridge the gap through the first dielectric 44 and decompose and partially ionize the first dielectric and a portion of the additional dielectric by radiant and convective heat transfer to produce a plasma which will form a plasma jet to feed a fuel of partially ionized ethylene to the oxidizer means containing chamber 56.
The plasma temperature will be greater than the temperature in the oxidizer chamber in order to ensure flow from the fuel chamber of the cartridge into the oxidizer chamber and not the other way around. In one embodiment, a plasma temperature of 10,000° K. would be desired. The hot jet of decomposed and partially ionized polyethylene fuel will be injected into the oxidizer chamber at a velocity of several thousand feet/sec. which will cause turbulent mixing of the fuel and the oxidizer creating a very large surface area which combined with the high temperature will make the reaction in the oxidizer chamber proceed instantly. The reaction can be controlled by metering the availability of fuel in the oxidizer chamber which can be accomplished by varying the geometry of the capillary, the surface area of the dielectric and the voltage across the plasma cartridge. Sonic flow through a nozzle created by the inwardly extending projections 52 forming the orifice or gate means is designed such that the mass flow rate is independent of pressure in the oxidizer chamber. It is expected that the additional dielectric 40 will be partially ablated after the first dielectric, which sublimated, depleted or otherwise discharged into the oxidizer chamber. The first dielectric may be in the form of small spheres of insulator material. The additional dielectric will be similar to the first dielectric.
The reaction of the fuel and oxidizer will generate hot pressurized gasses which expand to provide pressure to the base of the projectile to move the projectile down the barrel. The amount of electrical energy to pump the fuel, utilizing the plasma pump, is estimated to be about 10% of the overall energy of the gun thus providing, in a preferred embodiment, a ten fold pressure amplification. As the projectile moves down the barrel the additional space which becomes available can be filled by additional gases resulting in constant pressure and constant peak acceleration of the projectile if the voltage across the plasma generator and therefore the injection and combustion rates are programmed to increase with time proportionally to the volume generated by the projectile travel.
An alternative fuel, to the preferred hydrocarbon polymer, could be lithium hydride (LiH) which could be in pellet form to fill the capillary of the cartridge while an alternative oxidizer could be concentrated nitric acid or liquid oxygen (LOX). It may also be appropriate in some designs not to load the capillary with a first dielectric. In this alternative embodiment the additional dielectric will enclose the free space previously occupied by the first dielectric. An alternative structure, not shown in the drawing figure, would utilize a thin conductor or fuse from the first conductive means to the gate means area of the second conductive means. In this embodiment the capillary could be deleted (although it may be more desirable to utilize the capillary structure as a container for the first dielectric) and the additional dielectric surrounding the fuse could be such that the capillary is not present in the device. Upon electrical energization of the first conductive means a voltage would be imposed between it and the second conductor along the fuse. The metallic plasma generated by the fuse would ionize and ablate the dielectric such that a dielectric plasma is formed. The dielectric plasma would then serve as a pump means to deliver fuel to the oxidizer chamber as described above.
Thus it has been shown that a combustion augmented plasma pressure amplifier has been provided that has characteristics that make it ideal for use as a propulsion system for guns and the like. Nuances of design and variations in the details of the CAP gun embodiment specifically illustrated are contemplated by the inventors. The following claims, which are not intended to limit the scope of this invention, attempt to define the spirit of the invention. | A propulsion device uses an electrically driven plasma injector to feed combustible fuel into a chamber prefilled with an oxidizer. A reaction between the two constituents augments the electrical power input to produce amplified pressure for the acceleration of projectiles. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 USC §119 to German Patent Application No. 10 2013 019 666.3 filed on Nov. 22, 2013, which application is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention concerns a control apparatus, a motor regulator and a control method for controlling an electric motor, in particular a ventilator fan for motor vehicles, by means of a pulsed control signal.
BACKGROUND OF THE INVENTION
[0003] The standard “Local Interconnect Network” (LIN) was developed as a specification for a serial communication system as a new de-facto standard in particular for inexpensive communication of intelligent sensors and actuators in motor vehicles. The LIN serves in particular for inexpensive communication and is based on a one-wire bus which can be associated with the field buses. The LIN is composed of a master device and one or more slave devices. The master device has knowledge about the temporal sequence of all data to be transmitted. Those data are transmitted by the corresponding slave devices when they are required to do so by the master device. That is effected by sending out a message header characterised by a given message address. Subsequently the slave device connects its data output to the bus.
[0004] The new LIN standard is also intended for communication between control devices and motor regulators for electric motors in motor vehicles. Thus for example voltages or currents in radiator cooling fan regulators and interior fan regulators are regulated by means of corresponding signals or messages by way of various interfaces like for example pulse width modulation (PWM) and LIN. In that case an LIN interface has the advantage of greater flexibility over a PWM interface as various messages can be communicated while the PWM interface can only deliver a signal frequency and a pulse duty cycle. In the case of the PWM interface, it was possible to achieve a certain degree of flexibility by a variation in the pulse duty cycle, for example between 0% and 100%.
[0005] FIG. 2 shows a diagrammatic time graph of a PWM signal in pulse form, showing the period duration T, the pulse duration t PD and the pulse pause t PP . In this case the frequency of the PWM signal occurs as the inverse of the period duration, that is to say f=1/T.
[0006] As many control systems are based on a PWM-based control there is a need for backward compatibility so that conventional PWM-based devices can communicate with more recent LIN-based devices, that is to say the information which can be transmitted by means of the LIN can also be transmitted by way of a PWM-interface.
SUMMARY OF THE INVENTION
[0007] Therefore the object of the present invention is to improve a PWM-based control system to the effect that use is possible in conjunction with more recent control components which expect LIN-specific information.
[0008] That object is attained by a control apparatus as set forth in claim 1 , a motor regulator as set forth in claim 7 and a control method as set forth in claim 11 .
[0009] Accordingly a parameter set for controlling the electric motor is defined by an operating mode which in turn is linked to the pulse frequency of the pulsed control signal so that the selected value assignment for the parameter set can be signaled to the electric motor by means of the pulsed control signal. The signaled pulse frequency of the control signal is communicated to the motor regulator of the electric motor and detected there, wherein the parameter set for operation of the electric motor is determined in dependence on the detected pulse frequency.
[0010] It is also possible to provide different frequencies or frequency ranges (frequency windows) for a plurality of operating modes so that parameter values like for example overcurrent thresholds, overvoltage thresholds, fan switching frequencies, current rise and fall limits and so forth can be signaled.
[0011] Switching over to another parameter set is thus possible by simply changing the frequency of the control signal.
[0012] In addition the proposed signaling method can also be used for selecting between a normal mode and a test mode. Adjustment of the pulse frequency can be effected directly by way of a frequency-determining element or a frequency-determining circuit or by changes to the period duration by means of suitable time-determining element or a suitable time-determining circuit.
[0013] Establishing the parameter set in accordance with the operating mode can also be implemented in dependence on a predetermined motor manufacturer so that the control system can be adapted to different manufacturers of electric motors like for example ventilator fans or the like.
[0014] Further advantageous developments are recited in the appendant claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention is described in greater detail hereinafter by means of embodiments by way of example with reference to the accompanying drawings in which:
[0016] FIG. 1 shows a schematic block circuit diagram of a control system according to the first embodiment,
[0017] FIG. 2 shows a time graph of a PWM-control signal,
[0018] FIG. 3 shows a table with a first assignment specification between frequencies and parameter-determining operating modes, and
[0019] FIG. 4 shows a second table with assignment specifications between frequencies and parameters.
DETAILED DESCRIPTION
[0020] Set out hereinafter is a description of a preferred embodiment by way of example with reference to a control system of a ventilator fan motor in a motor vehicle.
[0021] FIG. 1 shows a schematic block circuit diagram of the control system in which a motor regulator 20 (here: fan regulator) for an electric motor (here: fan motor (M)) 30 is controlled by way of a PWM signal provided in a control device 10 . General regulation of the fan motor 30 is effected by way of a control input signal 200 which is passed to a PWM-control unit (PS) 16 , the PWM-control unit 16 generating a PWM-signal whose pulse duration or duty cycle is altered in dependence on the control signal 200 . The PWM-control signal is passed to a fan control (LS) 29 in the fan regulator 22 , which then controls the fan motor 30 in accordance with the control input signal 200 . The control input signal 200 can also involve a control signal 200 generated in dependence on a feed-back signal from the fan motor 30 so that a closed control loop is formed for regulating the fan motor 30 .
[0022] In accordance with the embodiment the control device has an additional input for the selection of an operating mode or a parameter set, by way of which a parameter control signal 100 can be input. The parameter control signal 100 can be input manually by a user or can be generated automatically by the control system in dependence on environmental conditions and/or other system-relevant properties. The control device 10 includes a selection unit (A) 12 which receives and evaluates the parameter control signal 100 and, in dependence on the parameter control signal 100 , selects an assigned operating mode and/or an assigned parameter set. That can occur in dependence on a storage table, an address memory or other link or logic circuits. The selection of the operating mode or the parameter set is passed to a frequency selection unit (F) 14 which feeds the pulse control unit 16 with a suitable control signal for establishing the frequency of the PWM-control signal. That conversion of the operating mode or the parameter set into a frequency in respect of the control signal can also be implemented on the basis of a storage table, an addressable memory, a selection circuit or a logic circuit. Conversion of the parameter control signal 100 into the frequency selection signal of the frequency selection unit 14 can also be implemented by a one-time conversion in an individual storage table, an individual addressable memory, an individual selection circuit or an individual selection logic means.
[0023] As can be seen from FIG. 1 therefore, besides the pulse width or pulse duty cycle information in respect of the PWM-control signal, additional information in regard to the operating mode or the parameter set can be transmitted by the frequency of the PWM-control signal to the fan regulator 20 . As shown in FIG. 1 firstly an operating mode B 1 at a lower frequency in respect of the PWM-signal is transmitted and later a second operating mode B 2 at a higher frequency in respect of the PWM-signal is transmitted.
[0024] At the fan regulator 20 the PWM-signal is passed to an interface (SS) 22 which feeds the PWM-control signal to the fan control 29 . In addition the PWM-signal or at least a signal corresponding to the frequency of the PWM-control signal is passed on to a detection unit (E) 24 which detects the frequency of the PWM-control signal and passes the result of the detection step to an adjusting unit (S) 26 . The adjusting unit 26 performs corresponding parameter setting in dependence on the signaled parameter set or the signal operating mode and stores the signaled parameter set in a first parameter memory (P) 28 .
[0025] The fan control 29 can thus access the parameter memory 28 and acquires the parameter set desired for the currently prevailing operating mode or the currently prevailing parameter choice, for control of the fan motor 30 .
[0026] The blocks of the control device 10 and the fan regulator 20 shown in FIG. 1 can be in the form of discrete hardware circuits, logic digital circuits, gate arrays or programmable logic circuits (PLDs) or software-controlled processors.
[0027] In a first practical example of the embodiment, corresponding to the table shown in FIG. 3 , it is possible to select between a test operating mode and a normal mode for example by way of the frequency of the PWM-control signal. Thus for example at a frequency f=50 Hz, it is possible to set a normal mode B N of the fan regulator 20 while at a frequency f=120 Hz of the PWM-control signal the fan regulator 20 is put into a test operating mode B T . Specific values can be assigned to predetermined parameters as further frequencies or frequency windows with additional operating modes, in which case the parameters can be for example overcurrent thresholds, overvoltage thresholds, fan switching frequencies, current rise and current fall limits and so forth.
[0028] Referring to FIG. 3 for example in addition to the normal operating mode and the test operating mode at a frequency f=300 Hz of the PWM-control signal, an operating mode B 25-16 is set, in which case the overcurrent threshold is 25 A, the fan switching frequency is 16 kHz, the current rise is at a maximum 7 A/s and the current fall is at a maximum 20 A/s. In addition an operating mode B 32-20 is signaled by a frequency f=400 Hz of the PWM-control signal, in which case then the overcurrent threshold is 32 A, the fan switching frequency is 20 kHz, the current rise is at a maximum 10 A/s and the current fall is at a maximum 30 A/s.
[0029] Different operating modes or parameters can then also be transmitted by switching over between different frequencies of the PWM-signal. Thus for example after the expiry of a predetermined period of time (for example a second) another frequency (and thus another parameter set and thus another operating mode) could be signaled. It will be appreciated that, instead of establishing the frequency, it is also possible to apply the period duration of the PWM-control signal.
[0030] To reduce the tolerance in respect of frequency or period measurement it is also possible to use a reference frequency (or reference period). Thus for example a frequency f=500 Hz can be transmitted as a fixed frequency while all other frequencies can be established proportionally thereto. The time until all parameters are transmitted and the first parameter occurs again can also be predetermined as the reference. As a further practical example, various frequencies of the PWM-signal can also be signaled for signaling respective users or manufacturers and correspondingly predetermined required characteristics of the control system, in which case another frequency of the PWM-signal is associated with various users or manufacturers.
[0031] FIG. 4 shows a table of a further practical example in which a range-dependent linear control of the maximum current of the fan regulator 20 or the switching frequency of the fan regulator 20 can be signaled. As shown in FIG. 4 in a frequency range of between f=50 Hz and f=150 Hz control is implemented linearly or successively from a maximum current I max =10 A to a maximum current of I max =30 A, while between a frequency f=170 Hz and a frequency f=250 Hz of the PWM-control signal a switching frequency of between 17 kHz and 25 kHz can be signaled. Thus continuous or successive current limitation to 10 A (at f=50 Hz) to 30 A at (f=150 Hz) and continuous or successive regulation of the switching frequency of the fan regulator 20 is accordingly possible.
[0032] It will be appreciated that any other links between the frequency of the PWM-control signal and predetermined parameters, operating modes or parameter sets can readily be envisaged and are comprehensible to the man skilled in the art. Thus different types of fan motors or ventilating blowers from the same or different manufacturers can also be signaled by different frequencies of the PWM-control signal.
[0033] The present invention is not limited to the fan motor control in accordance with the above-described embodiment but can be used for the most widely varying motor control and regulating situations in dependence on pulsed control signals in order thereby in addition to pulse width control also to permit a transmission of operating modes or parameter sets. The fan regulator 20 shown in FIG. 1 can be separate from the fan motor 30 or can be integrated thereinto. | The present invention concerns a control system for an electric motor, wherein an operating mode with predetermined value assignments is selected for a parameter set for controlling an electric motor and the pulse frequency of a control signal for the electric motor is set in accordance with the selected operating mode in order thereby to signal to the electric motor the selected value assignments for the parameter set. | 7 |
This application is a division of original application Ser. No. 08/194,722, filed Feb. 14, 1994, now U.S. Pat. No. 5,404,908.
BACKGROUND OF THE INVENTION
The invention relates to an electromagnetically operated valve construction, wherein a single magnetic circuit places plural valve members of magnetic material in series magnetically interlinked relation, so that a single electrical excitation coupled to the single magnetic circuit can simultaneously operate the plural valves and thus simultaneously control independent flows of separate pressure fluids through the respective valves.
U.S. Pat. Nos. 3,443,585, 3,472,277 and 4,223,698 disclose various magnetically actuated valve systems wherein a single electromagnetic excitation will actuate each of two valve members, each of which serves its own pressure-fluid flow. In U.S. Pat. No. 3,443,585, a permanent magnet is the common middle leg of two separate solenoid-actuated magnetic circuits. Excitation of one solenoid opens both valves; excitation of the other solenoid closes both valves, and the permanent magnet holds the actuated condition of both valves. U.S. Pat. Nos. 3,472,277 and 4,223,698 each disclose an electromagnetic actuating system wherein a single solenoid coil actuates two magnetically linked valves to open condition, against the compliant action of springs to load valve members in the valve-closing direction. In all cases, construction is highly specialized and complex, leading to unduly expensive products.
BRIEF STATEMENT OF THE INVENTION
It is an object of the invention to provide an improved electromagnetically actuated multiple-valve construction of the character indicated.
A specific object is to meet the above object with a novel valve-body construction and method of making the same, lending itself to greater precision in the final product and requiring materially less manufacture of subassemblies that must be assembled to each other.
Another specific object is to achieve the foregoing objects with a minimum number of seals to assure against leakage and/or mixture of separate pressure fluids that are being independently controlled by the respective valves of the system.
The invention achieves the foregoing objects by relying upon a valve-body construction wherein relatively thick non-magnetic and magnetic slabs are bonded into a consolidated body block, in laminated alternation, prior to machining the same to serve the dual-valve purposes of the invention. In the embodiment to be described, the uppermost slab is non-magnetic, the next-adjacent slab is magnetic, and the lowermost slab is non-magnetic. Two spaced guide bores through the body block accommodate movement of separate valve members of magnetic material; the upper end of each of these valve members is upwardly exposed in confronting relation with one to the exclusion of the other pole face of the U-shaped core of an electromagnet, whereby a single magnetic circuit, established by the U-shaped core and the valve members, relies upon the middle slab of magnetic material to complete the circuit by magnetically linking both valve members. Inlet and outlet flows of pressure fluid pass through separate chambers formed primarily in the lowermost slab on the respective guide-bore alignments. Except for a valve-seat and outlet, each valve chamber is closed at its lower end, and spring means reacting between the pole faces of the U-shaped core and the respective valve members normally urge the valve members into seated, valve-closed coaction with their valve seats. Electrical excitation is effective to displace both valve members to valve-open position, against preloaded spring action; and the preloaded spring action assures valve closure when electrical excitation ceases.
DESCRIPTION OF THE DRAWINGS
The invention will be described in detail for a preferred embodiment, in conjunction with the accompanying drawings, in which:
FIG. 1 is a vertical section through a twin-valve system of the invention, wherein the section plane is defined by the displacement axes of the respective valves; and
FIG. 2 is a simplified isometric diagram of valve-body structure in FIG. 1.
DETAILED DESCRIPTION
In the description which follows, the expressions "upper", "upward", "lower", and "downward" are used to simplify description of the orientation shown in the drawings, and it will be understood that the structure to be described can function in any orientation, i.e., without the gravitational context that might otherwise be suggested by such expressions. Also, the expressions "magnetic" and "magnetic material" will be understood to apply to the property of conducting magnetic flux, whereas the expressions "non-magnetic" and "non-magnetic material" will be understood to apply to a relative inability to conduct magnetic flux.
Referring initially to FIG. 1, the invention is shown in application to an electromagnetically operated valve of the normally closed variety, wherein a single electrical winding or solenoid 10 is excited to concurrently open two valves, by upwardly displacing their respective valve members 11, 12 from their valve-closed position shown. A first pressure-fluid passage is thus opened between an inlet 13 for a first-fluid flow A to an outlet 14, via a valve-seat formation 15; at the same time, a second pressure-fluid passage is also thus opened between an inlet 16 for a second-fluid flow B to an outlet 17, via a valve-seat formation 18. Separate preload springs 19, 20 normally urge the respective valve members 11, 12 to valve-closed position, i.e., in the absence of electrical excitation of winding 10. The valve members 11, 12 are guided for axial displaceability on axes 21, 22 which define an upstanding geometric plane and which are oppositely inclined for convergence in the downward direction. Such convergence is not a requirement of the invention but it is a useful feature when the valve is to serve flows of reacting propellant fluids (more commonly called propellants), such as nitrogen tetroxide (oxidizer) at A and monomethyl hydrazine (fuel) at B to the combustion chamber of a rocket engine at B to the combustion chamber of a rocket engine (not shown), but fitted to receive the separate A and B discharges via valve outlets 14, 17.
A phantom double-line loop 24 in FIG. 1 schematically indicates the path of magnetic flux in the magnetic circuit, in response to excitation of winding 10. As shown, this path is established by a cylindrical magnetic element 25 which is the central portion of a generally U-shaped core including two spaced downwardly directed magnetic legs 26, 27, establishing pole faces 28, 29, each of which, in the valve-closed position shown, is spaced by a short gap to the confronting upper-end face of one of the valve members 11, 12. The valve members 11, 12 are of magnetic material, and a central magnetic part 30 of valve-body structure 31 enables the valve members and part 30 to complete the magnetic circuit (24) that is excitable by winding 10.
Each of the valve members 11, 12 is axially elongate, having an upper portion 33 (34) that is cylindrical, with guided running clearance within a guide bore 35 (36) centered on one of the axes 21 (22). Cylindrical bores in each pole face 28 (29) confront opposing cylindrical bores in the upper end of each valve member for centered location of the preload springs 19 (20). As shown, each guide bore 35 (36) continues downward to establish a valve-chamber wall 37 (38) that communicates with the respective inlet passages 13 (16); and throughout the valve-chamber region each valve member 11 (12) is of slightly reduced diameter, in generous radial clearance with chamber-wall structure. The lower end of each guide bore 35 (36) terminates short of the bottom of the valve body, except for the valve-seat and outlet-passage formations previously noted. Finally, the lower end of each valve member is fitted with a poppet element 39 (40) having sufficient resilience to assure valve closure at its position of valve-seat engagement.
Filtering means 41 (42) are schematically shown in the respective inlet passages 13, 16 for removal of any solid matter which might impair the fidelity of valve-open, valve-close action in response to electromagnetic valve-opening actuation via winding 10, or valve-closing preload actuation via springs 19, 20.
The construction and nature of valve-body structure 31 is an important feature of the invention and will be discussed in further reference to FIG. 2 of the drawings.
The body structure 31 is basically a prismatic block comprising three flat slabs 51, 52, 53 of magnetic and non-magnetic materials that have been bonded in face-to-face relation prior to machining of any of the bores or other features of the valve body. In the construction shown, the first or lowermost slab 51 is non-magnetic and is relatively thick, sufficient to be machined (after consolidation with slabs 52 and 53) for definition of the valve-chamber walls 37, 38, as well as the respective inlet passages 13, 16 communicating therewith, and the valve-seat and outlet-passage formations. The second or intermediate slab 52 is of magnetic material, of lesser thickness that is nevertheless sufficient to establish the short bridging flux-path connection 30 which completes linkages of the two valve-members in the magnetic-circuit loop 24. And the third or uppermost slab 53 is also relatively thick, for stable guidance availability for the valve members, via bores 35, 36. The three slabs may be bonded or otherwise permanently consolidated to the block from which body 31 is later machined, but a preference is indicated that these slabs be initially characterized by relatively rough surface texture and that they be consolidated by the technique known as inertia-welding, wherein friction at slab-to-slab interfaces establishes a permanent fusion of the slabs to each other. Reference is made to an undated booklet, "Interia/Friction Welding-Application Principles", available from Interface Welding, Carson, Calif., for discussion of inertia welding which is not per se a part of the present invention.
The most important machining operation is the formation of the two upwardly open bores 35, 36 which serve as valve-member guide bores in their passage through the second and third slabs 52, 53, and which serve to provide valve-chamber walls in their limited passage into the lowermost slab 51. Tooling for this machining will depend upon hardness properties and tolerance specifications for three slabs, and EDM machining is well suited to the purposes, including the formation of a valve seat at the bottom of each of these bores. The same may be said for the small-diameter bores of outlet passages 14, 27 and for the lateral boring needed in slab 51 to provide inlet passages 13, 16, insofar as these passages are within the body block 31. It is difficult in a single diagram to depict all details of such machining, but lightly dashed elongate outlines at 35', 36' between phantom ends 35a, 35b (36a, 36b) can be taken as suggestive of the valve-guidance portion of bores 35, 36 through slabs 52, 53; and the lightly dashed elongate outlines at 35", 36" between phantom ends 35b, 35c (36b, 36c) can be taken as suggestive of the valve-chamber portion of bores 35, 36, extending well into the lowermost slab 51.
Before assembly of the U-shaped core (and its winding 10) to the bored block 31, the respective valve members 11, 12 (which will be understood to have been separately fabricated) and their preload springs 19, 20 are assembled to body block 31 via the open ends of bores 35, 36, and to the point of poppet (39, 40) engagement with associated valve seats 15, 18.
FIG. 2 also shows magnetic components of the U-shaped core which must be secured to the body block 31. Each of the spaced legs 26, 27 of this core is seen to comprise a short cylindrical pole-face region 26', 27', with remaining upwardly projecting leg structure that is interconnected by the central core element 25 (about which winding 10 is developed). The lower surface of each pole face region 26', 27' is truncated at an inclination (see FIG. 1) which uniformly confronts the slope of the upper end of the valve member with which it is to react. And counterbores 54, 55 at the upper end of bores 35, 36 are sized for accurate insertional location of the pole face regions therein, with the upper ends of springs 19, 20 located in the spring-retaining bores of the pole faces. As seen in FIG. 1, the pole-face connections to counterbores 54, 55 are completed and made permanent by peripherally continuous welding, preferably electron-beam welding, suggested at 56, 57.
Upon thus-welded consolidation of pole-face connections to the counterbores 54, 55 of the non-magnetic upper slab 53 (it being understood that winding 10 is incorporated in such consolidation of its core connections), the magnetic and electromagnetic components, as well as the fluid passages to be controlled thereby, are functionally complete. All that remains is complete an enclosure of the electromagnetic means 10, 25, 26, 27. Such enclosure is shown in FIG. 1 as a cupped cover 58 having a grooved peripheral flange for sealed engagement to ledge means 59 of the body block, and this sealed engagement may be compressionally loaded, as by a peripheral succession of spaced bolts (not shown). Finally, a preference is indicated for potting all unused voids within the described structure, the same being suitably accomplished by a vacuum-induced epoxy filling 60. And, to assure against the remote possibility of fluid leakage through an insufficiently bonded slab-to-slab interface, through-bores 60, 61 open at both ends of the body block 31 intercept the interface between slabs 51, 52 and the interface between slabs 52, 53, exposing any such leakage to ambient atmosphere.
The described structure will be seen to meet all stated objectives. In particular, the described structure and the described method of manufacture offer important advantages, some of which are listed below:
1. The so-called "dribble" volume, which is the volume of the outlet passages 14, 17 and of the connecting inlet passages (not shown) of any device, such as a rocket engine to be connected to the bottom surface of slab 15, must be minimized when the described multi-valve system is used to control the flow of rocket-engine propellants, in order to obtain high efficiency and highly repeatable operation of the rocket engine. The present invention allows outlet passages 14, 17 to be very close together (for example, 0.350-inch spacing, center-to-center, in a rocket engine that produces 0.25-lb. thrust). This feature allows the "dribble" volume of a mating rocket-engine injector to be very small indeed.
2. The friction or inertia-welding method referred to above is preferred, for any rocket-engine applications of the invention. This preference is stated with respect to any other alternative slab-joining techniques, such as the use of "filler" or "brazing" material. This preferred method thus specifically avoids any possible incompatability of a filler material with valve effluent(s).
3. The two valve members 11, 12 operate with near-simultaneity, even though one of these members may start to move before the other, due, for example, to preload tolerances, or pressure differences, or gap differences at 28/29. The near-simultaneity of these actions is attributable to the "magnetically linked" relation of the valve members to the involved magnetic circuit, in that the force on the lagging member increases or decreases quickly in the direction to foster simultaneous displacement of both valve members. | The invention contemplates a method of making a valve body for a magnetically actuated twin-valve system, wherein the valve body comprises a body block of three relatively thick slabs vertically bonded to each other and to the consolidated height of their combined thicknesses, the first and lower most slab being of non-magnetic material, the second and intermediate slab being of magnetic material, and the third and uppermost slab being of non-magnetic material; the method comprises the steps of (a) inertia-welding said slabs to each other; and (b) machining first and second spaced valve-member guide bores through said second and third slabs and through at least a portion of said first slab, with a valve-seat opening at the otherwise closed lower end of each bore of said first slab and with independent lateral-access inlet-port communication with the respective bores in said first slab. | 5 |
FIELD OF THE INVENTION
The present invention generally relates to the field of monitoring and access of the utilization of programs and devices as pertaining to information handling systems, and particularly to the use, manipulation, and access of representations of prior and current usage.
BACKGROUND OF THE INVENTION
Today, users of information handling systems have access to a wide range of resources. For example, faster processors and expanded memory enable a user to operate more than one program at a time, as well as connect an increasingly greater variety of devices to the information handling system, such as printers, modems, touch pads, write pads, voice recognition devices, satellite information, network access, etc. The variety and sheer number of available devices and resources connected to even one system may make tracking the performance and utilization of these resources near impossible, especially if the system is connected to a network. A user operating a typical information handling system may generally determine which programs are currently operating, but may not determine how they are operating, which tasks are being performed, or the utilization by the program of devices connected to the system. Additionally, a user may not have a clear idea of the past usage of the system. Errors may occur as a result of a downloaded document, incomplete installation, or malfunctioning device. Without the ability to view past usage and the association of various programs utilized, a user must merely guess at the cause of the problem.
In some instances even when the past usage of a resource is stored, the user may not determine the association of the resources. For example, a web browser may save accessed web sites saved in a history section displayed in alphabetical order relating to a specified unit of time. These saved histories are capable of accessing the previous item stored on the system or connecting through an active connection to access the resource, such as a web page. However, even though the relationship of a web page may be displayed as it pertains to the specific site, the association of the web pages to each other may not be shown. For instance, a user may determine that a particular site was accessed during a particular time and that a particular page is a component of a particular site, but the user may not determine the association of the sites with each other, such as the order the sites were accessed, the organization structure of the sites, how the sites were accessed, etc. Secondly, a user may not apply this information to other actions taken on an information handling system, such as the utilization of devices, programs, etc.
Furthermore, current usage of a system is typically stored in a chronological fashion. For example, sites visited by a user during a browsing session are typically listed in the order accessed. If a user accesses an initial site, then a second site, and then accesses the initial site again, the history is shown as initial site, second site, initial site. In other instances, a history of the current browsing session may merely show repeated accessing of the main site, even though pages within the site were accessed. Therefore, it may be advantageous to show prior access of resources and utilization of an information handling system by a user in organizational scheme so the association of the resources, devices, etc. may be communicated.
Additionally, users of current web browsers and operating systems may utilize navigation controls to navigate through sites and windows that were previously accessed by the user. However, once a user exits the program or terminates the system, this data is lost. For example, a user must then either try to remember the address to the desired site or save desired sites and pages as a “bookmark” or on a list of “favorites” to access the site after termination of the browsing session. Therefore, it may be advantageous to save navigation histories so as to be accessed later by a user to enable the utilization of the navigation history by the navigation functions included in the information handling system.
Therefore there is a need for a system and method for persistent usage context of an information handling system.
SUMMARY OF THE INVENTION
The present invention is directed to a system and method for generating a persistent usage context. In an exemplary embodiment, a method of generating a persistent usage context includes monitoring usage of an information handling system and generating a first representation corresponding to a first item of usage and a second representation corresponding to at least one of the first item of usage and a second item of usage. The first representation and second representation are communicated so as to communicate an association of the first representation to the second representation and to enable a determination of at least one of the prior usage and current usage of an information handling system.
In another exemplary embodiment, a user may determine the current and prior usage of an information handling system both locally on the information handling system and over a network as well as determine the utilization of a plurality of information handling systems. By utilizing representations depicting current and prior items of usage, such as the operation of a word processor, spread sheet, email, device, etc., a user may view activities performed on the system as well as the association of the activities. In this manner, a user may determine which programs are currently operating, which tasks are being performed, and the utilization by the program of devices connected to the system. This may also enable a user to determine the source of problems which occurred on the system by viewing a usage history of tasks and actions performed by the system. Furthermore, in another embodiment a user may access information and actual tasks and programs utilized by the system by utilizing the representation.
In a further exemplary embodiment, representations may be displayed in an organizational scheme. In one example, representations depicting the usage history of an information handling system may be communicated so as to disclose the association of the resources as utilized by the user.
In an additional exemplary embodiment, the present invention is directed to a system and method wherein a persistent usage context, for instance navigation in a web browsing session, operating system, etc. may be stored. The method of generating a persistent usage context includes monitoring the navigation of a resource during a first navigation session to obtain navigation data and storing navigation data pertaining to the first navigation session. Then, the method involves initiating a second navigation session of at least one of the first resource and a second resource and loading stored data in at least one of the first resource and the second resource so as to enable the utilization of stored first navigation data during the second navigation session. For example, this may enable a user to store web browsing contexts for later use even after the web browsing session has terminated. In a preferred embodiment, saved usage contexts may be stored and selectively accessed on a user's information handling system. In another embodiment, the persistent usage context may act to load previously accessed sites into a user's web browser to enable the user to utilize the forward and backward buttons as if the web session were still active.
It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and together with the general description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:
FIG. 1 is an illustration depicting an exemplary embodiment of the present invention wherein a persistent usage context communicates representations corresponding to items of usage in chronological order;
FIG. 2 is an illustration depicting an exemplary embodiment of the present invention as depicted in FIG. 1 wherein representations of items of usage including email usage are shown;
FIG. 3 is an illustration depicting an exemplary embodiment of the present invention as shown in FIG. 1, wherein a representation may be accessed by right clicking a mouse while a cursor is disposed proximally to a representation to access information and properties corresponding to the representation;
FIG. 4 is an illustration depicting an exemplary embodiment of the present invention as shown in FIG. 1, wherein an association including the utilization of devices and time required to perform an item of usage is communicated utilizing representations;
FIG. 5 is an illustration depicting an additional exemplary embodiment of the present invention wherein a menu bar containing a view menu is shown;
FIG. 6 is an illustration depicting an exemplary embodiment of the present invention as shown in FIG. 5 wherein a menu bar containing an edit menu is shown;
FIG. 7 is an illustration depicting an exemplary embodiment of the present invention as shown in FIG. 1 wherein a search function including exemplary searchable criteria is shown;
FIG. 8 is an illustration depicting an exemplary embodiment of the present invention as shown in FIG. 1 wherein a property function capable of being displayed as a pop-up menu is shown;
FIG. 9 is an illustration depicting an additional exemplary embodiment of the present invention as shown in FIG. 8 wherein an exemplary property function window is shown;
FIG. 10 is an illustration depicting an exemplary embodiment of the present invention wherein a lexicon of representations is shown;
FIG. 11 is an illustration depicting an exemplary embodiment of the present invention as shown in FIG. 10 wherein a combination of representations may be displayed;
FIG. 12 is an illustration depicting an exemplary embodiment of the present invention wherein representations are combined;
FIG. 13 is an illustration depicting an exemplary embodiment of the present invention wherein a high level organization scheme is shown;
FIG. 14 is an illustration depicting an exemplary embodiment of the present invention wherein a medium level organization scheme is shown;
FIG. 15 is an illustration depicting an additional exemplary embodiment of the present invention wherein previous navigation data may be utilized in a current navigation session;
FIG. 16 is an illustration depicting an additional exemplary embodiment of the present invention wherein separate navigation bars may be utilized to access stored and live usage data; and
FIG. 17 is a block diagram of an information handling system operable to embody the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the presently preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
Referring generally now to FIGS. 1-16, a persistent usage context may be utilized in an exemplary embodiment of the present invention to communicate both prior and current usage of an information handling system. Usage for an entire information handling system, including the utilization of programs, operating systems, devices coupled internally, peripherally and over a network, a plurality of information handling systems, network applications, etc. may be communicated by utilizing the present invention. In one embodiment usage may be displayed as representations, such as icons, thumbnails, etc. that correspond to an item of usage. Associations of the items of usage may be communicated through a variety of ways, including spatial relationships, temporal relationships, arrows, organizational schemes, etc. In this way, the present invention may overcome the limitations of an alphabetical listing of previously accessed resources and the mere display of resources in a nested format.
Referring now to FIG. 1, an exemplary embodiment of the present invention is shown wherein a usage history is communicated in a chronological order. A persistent usage context 100 may utilize a window 110 that may appear on a display of an information handling system. The persistent usage context 100 may be implemented under an operating system such as Windows® 98. The window 110 may have standard controls for maximizing 112 , minimizing 114 , and closing 116 the window 110 . A range of time 120 may be displayed in an area of the window 110 . The time range 120 may include boxes for displaying intervals 122 of the time range. Within each time interval 122 , representations 124 , in this instance shown as icons, may be displayed to show which type of resource was utilized by the system during the time interval 122 . Time intervals 122 may also include controls for adding 126 and removing 128 representations to and from a detailed description area 150 . The time range 120 portion of the window 110 may also include controls for scrolling up 130 and down 132 the time range. This may allow a user to scroll through many time intervals 122 of the time range 120 . Additionally, the time range 120 portion of the window 110 may include a date indicator 134 with scrolling controls 136 to have information from various dates appear in the time range 120 .
A detailed description area 150 may be included to communicate present and historical usage information. In an exemplary embodiment, the detailed description area 150 may include an association depicted as a line of representations 152 for each instance of utilization of a resource, such as a word processor, email program, etc. Furthermore, associations including multiple representation lines 152 may be displayed for communicating information regarding the utilization of multiple resources by an information handling system, network of information handling systems, etc. A representation 154 may be displayed for individual resources or media pieces, such as documents generated from a word processor, spread sheets, email messages, etc. A selector control 156 may be utilized to allow a user to choose a particular time. For example, a selector control 156 may slide up and down a window 110 to allow a user to select the full viewing context as it existed at that time. Additionally, a default load control 158 may be utilized to set the default load, such as live or stored. For example, a user may access a live version of the utilization, such as a web page over the Internet or a stored version contained on the user's system. In a preferred embodiment, a user moving a cursor over a representation 160 may access a view of the usage. For example, a user moving a cursor over a representation 160 of a web page may view a thumbnail picture 162 of the page and controls 164 to allow opening of the page from a live or stored source. Additionally, it may be preferable to utilize indicators to signify if a resource is available 166 or not available 168 . Indicators may include displaying an “A” if available and an “N/A” if not available, using colored dots such as green for available and red for not available, etc.
An exemplary method for the utilization of the present invention as shown in FIG. 1 will now be discussed. A user has accessed the details of the utilization of an information handling system on February 17 between 7 and 10 PM. The time intervals between 7 PM to 10 PM include one television show 172 , three web pages 170 , a word document 176 , and an excel document 174 . In this example, the excel document 174 has been toggled off so as not to be displayed in the detailed description area 150 . It may be preferable to display a representation that has been toggled off by darkening the representation, shadowing the representation, etc. In this instance, a user has moved a cursor over a web page representation 160 to display a thumbnail 162 of the resource. The user may also access a representation, such as right clicking a mouse while the cursor is located proximally to the representation, and select properties to see a window to show detailed information about the resource.
Referring now to FIG. 2, a persistent usage context 200 wherein email representations 210 as utilized by the present invention are shown. A cursor disposed proximally to the email representation 210 may enable a graphic 212 to display relevant information about the representation 210 . In this instance, the graphic 212 may display when email was received. A representation may include another representation indicating that the event represented is the reception of an email 214 . Other representations may be generated to indicate more specifically the utilization of the system, such as a book icon 214 indicating that an email was viewed at that point in time, a pad and pencil icon 218 indicating that an email was composed, and an arrow pointing away from the email icon 220 , indicating that an email was sent, etc. Therefore, a user utilizing this exemplary embodiment may determine not only which general resource was utilized, but also the specific actions performed in that resource as well as the relevant associations. Furthermore, the actions and resource are displayed in a user friendly manner to enable quick viewing.
As shown in FIG. 3, a user may access a representation to perform a variety of actions. In this embodiment, a user may view a persistent usage context 300 in a window 310 displayed on an information handling system. The persistent usage context 300 may be implemented under an operating system such as Windows® 98. A user may access information contained in a representation 312 by moving a cursor over the representation, right-clicking a mouse when a cursor is disposed proximally to the representation, etc. A menu may be displayed, in this instance a pop-up menu 320 , to communicate relevant actions, options, and information that may be relevant to the representation 312 . In this instance, the menu 320 includes an “open” element. The open element may contain a submenu 322 to enable a user to choose between the latest stored version of the resource or the live resource. For example, a user may determine whether to access a stored version of a web page or access a “live” version through a network connection. A search function may be included in the menu to enable a user to search for a particular representation, time of utilization, particular resource, action performed, device utilization, etc. Other traditional actions may be accessed from the menu 320 . For example, cut, copy, and paste may function similarly to the standard in the Windows operating system. Cutting a representation from an association, such as a line of representations 330 , may break the association into two branches. Pasting a representation may start a new branch depicting an association and involve making a copy of the document within the history. This may be useful is a user desires to access and change a particular usage item but wishes an undisturbed copy of the usage item to remain on the system. A remove function may also be included on the menu 320 to remove a representation from display in the detailed description portion 150 (FIG. 1) of the window 310 . It may be preferable to retain the underlying item of usage by not deleting the item from the system when it is removed. Furthermore, a properties function may be included in the menu 320 to launch a properties view of the given item of usage.
The persistent usage context may also be utilized to communicate the status and time required for an action performed by an information handling system, as shown in FIG. 4 . In this embodiment, a resource, such as an anti-virus application, may be utilized to perform a virus scan of an information handling system. A representation of the anti-virus application 410 may be displayed in the persistent usage context 400 . A status bar representation 414 may be included to indicate the start of the scanning process. Once the virus scan is completed, an additional status bar representation 416 may be displayed next to the anti-virus application representation 410 to indicate the completion of the task. Furthermore, a pop-up menu 412 may be utilized to communication information pertaining to the performed task, in this instance that no viruses were found.
A persistent usage context may also be utilized to communicate usage of devices, as shown in FIG. 4 . In this exemplary embodiment, a persistent usage context 400 may communicate information pertaining to devices connected to an information handling system, in this instance a printer. A representation of a printer 420 may be utilized to communicate the availability of a printer to the system. Additionally, a plug representation 422 may be utilized in conjunction with the printer representation 420 to depict the connection of the printer to the information handling system. A variety of actions and functions may be communicated in a similar manner, such as communicating with devices over a network. Furthermore, representations may be utilized to communicate the actual utilization of a device, as well as the association of the device with a resource. For example, a printer may receive a printing job from a word processing program. By utilizing a printer representation 424 in conjunction with a representation depicting the processing of the print request 426 , the persistent usage context may display the time taken to process the request and from where the request was received 428 . It may be useful to enable a user to access the printer representation 424 to show the status of the print request. Therefore a user may be able to determine the current usage of an information handling system. It may also be useful to employ the present invention over a network so all devices connected to the network may be communicated and represented by the present invention. Additionally, the present invention may be employed by a server so as to monitor and display activity over a network.
A variety of menus may be utilized by the present invention to enable a user to access functions that may prove useful in the framework of a persistent usage context. One such function may be incorporated in the view menu, an example of which is shown in FIG. 5 . In this embodiment, a menu bar 510 may be located at the top of a window 502 in a persistent usage context 500 . A view function 512 may be located in the menu bar 510 to provide a variety of functions related to the viewing of the persistent usage context 500 . For example, a user may elect to display only a program usage history, and even further limit the view to productivity applications, entertainment applications, etc. In another example, a user, such as technical personnel, may wish to show only maintenance activity such as installed hardware and software, virus scans, etc. It may also be preferable to enable a user to change default setting, such as color, size of the detailed description window 150 and time range window 120 (FIG. 1 ), font type, time intervals displayed, format of the association of representations, such as chronological, organizational, linear, tree format, spatial, etc.
An additional menu that may be utilized in an exemplary embodiment of the present invention is the edit menu. As shown in FIG. 6, an edit menu 612 may be contained in a menu bar 610 of a persistent usage context 600 . The edit menu may contain standard edit functions, such as undo, redo, cut, copy, and paste, as described earlier. Furthermore, the edit menu may contain access to a search function to locate specific items of usage and representations contained in the persistent usage context 600 .
Referring now to FIG. 7, an exemplary embodiment of a persistent usage context 700 employing a search function is shown. In this example, a persistent usage context 700 utilizes a window 702 to display representations of items of usage. A search function displayed in a separate window 704 may be employed to communicate relevant data qualifying under a variety of elements. For example, a search may be performed by topic 706 of interest based on established structured query language (SQL) rules. Additionally, a user may define the scope 708 of the search function. For example, a drop-down list may be utilized to list forms of searchable media, such as by device (hard drive, compact disk read only memory, digital versatile disk, television, etc.), application, resource type, etc. The scope of the search may include multiple items listed in the scope function 708 that are then displayed 710 to the user. It may be useful to include temporal constraints on the search. For example, a user may specify beginning 712 and ending 714 dates and times to narrow the search. Furthermore, additional fields such as year and a list broken out by a specified amount of time, for example the last 7 days, last 24 hours, etc. may enable a user to customize a search request. Once the user completes the desired fields, the user may initiate the search by clicking a displayed button 716 . It may be desirable to include a progress bar 718 to inform the user of the status of the search request. The results of the search may be displayed 720 so a user may access the results directly from search window 704 . Results may be displayed with corresponding representations to enable a user to determine relevant usage data immediately from the search window 704 . For example, a user may “click on” a representation from the results window 720 to directly access the corresponding item of usage. It may also be preferable to search based on the representation utilized. Such a search may include custom fields implemented and modified by a user. For example, a user may wish to add fields and data to a representation. By allowing a user to search this additional information, a user may further customize a search request.
Referring now to FIG. 8, an exemplary embodiment of a persistent usage context 800 including a properties function is shown. In this example, a persistent usage context 800 utilizes a window 802 to display representations 804 of items of usage. A properties function may be initiated by “right clicking” a mouse while the cursor is disposed proximally to the representation 804 to display a pop-up menu containing the properties function 806 , may be contained in a menu bar, etc. to display a properties window 808 . It may be preferable to include a variety of properties 810 such as general, security, content, connections, programs, and advanced under the properties menu. A user may choose the desired property relevant to the particular representation and corresponding item of usage by utilizing this method.
An additional exemplary embodiment of a properties window included in a persistent usage context is shown in FIG. 9 . In this exemplary embodiment, a user may view particular properties relevant to a representation and corresponding item of usage. A properties window 910 may display a history of use for a corresponding representation 902 . In this instance, the usage history is included as a tab 912 in the properties window 910 . The usage history may include a list 914 of the utilization of the item of usage and the time utilized. Furthermore, a list of data types 916 may be included to display which types of data are contained in the item of usage.
Representations may be generated to indicate an item of usage and the source of the item of usage to which it pertains, examples of which are shown in FIG. 10 . In this exemplary illustration, a lexicon 1000 of exemplary representations is shown. Representations may indicate the applications and media 1010 to which they pertain. For example, representations for Microsoft® Internet Explorer® 1012 , Microsoft® Word® 1014 , Microsoft® Excel® 1016 , email 1018 , a virus scan 1020 , virus 1022 , Adobe® Photoshop® 1024 , sound file 1026 , home page 1028 or any other application may be generated to correlate to the relevant item of usage. Representations may be created from icons used to traditionally depict the program in a graphic user interface (GUI) or any other method used to generate a representation such as a thumbnail of a web site, etc.
Additionally, representations of actions and processes 1030 may be generated to indicate performance of a task by the item of usage. For example, representations may be used to indicate the progress of a task, such as when an action starts 1032 and stops 1034 . Additional examples include representations depicting when a device is added 1036 , a brief process being performed 1038 , sending or transmitting data 1040 , receiving data 1042 , viewing an item of usage 1044 , editing an item of usage 1046 , installing software 1048 , etc. to show actions performed by an item of usage. Furthermore, the availability of the item of usage 1050 may be indicated by the use of a representation. For example, the availability of a web page from a stored source on an information handling system or a live connection over a network may be indicated with a representation showing availability, such as an “A” 1052 or a green dot, or showing that the item of usage is not available, such as an “N/A” 1054 or a red dot. Additionally, if the source of the item of usage is stored on an information handling system, server, etc. a stored copy representation may be utilized 1056 . Likewise, representations for devices 1070 may be utilized by the present invention to indicate the usage of a device in conjunction with an item of usage, such as printing a document from a word processor, or items of usage pertaining to the device itself. For example, a server 1072 , computer 1074 , printer 1076 , compact disk read only memory (CD ROM) 1078 , floppy disk drive 1080 , hard drive 1082 , television 1084 , satellite system 1086 , video cassette recorder 1088 , modem 1090 , etc. may be represented to indicate usage of a device and how that usage is associated with available resources.
Representations may be combined to further indicate the performance of an item of usage. As shown in FIG. 11, representations in an exemplary embodiment of a persistent usage context 1100 are shown combined to more completely describe an item of usage. For example, a Microsoft® Internet Explorers representation 1102 may be used to indicate browsing the World Wide Web, that this particular web page is a home page 1104 , and that the item of usage if available live 1106 , such as through a network connection, modem connection, etc. Therefore a user may be able to determine that a web page utilized during a browsing session is available live. In another example, a user may have received an Adobes Photoshop® image and stored it on a hard drive. Therefore, representations may be generated indicating an Adobe® Photoshop® image 1108 , received 1110 , and then stored on a drive 1112 . In yet another example, a user may view a previously received email that is no longer available to be utilized. Therefore, an email representation 1114 indicating that the email was viewed 1116 but that it is no longer available 1118 may be generated. An almost endless variety of combinations of representations may be generated and utilized by the present invention by a person of ordinary skill in the art and not depart from the spirit and scope of the present invention.
Furthermore, representations may be combined to form an additional representation to comprehensively represent an item of usage, as shown in FIG. 12 . In this exemplary embodiment, a persistent usage context 1200 including web browsing is shown. A representation 1202 may be used to indicate a web page was accessed. Information regarding the web page may also be displayed by the representation 1202 , such as the web page is a home page 1204 , the name of the web site 1206 , and the address of the site 1208 . Information regarding the accessing of the item of usage may also be communicated. For example, representations indicating downloads 1214 , percentage of the document downloaded 1210 may also be shown to indicate the source of the item of usage. Additionally, information pertaining to content related to the item of usage may be communicated with the use of representations. For example, that the item of usage contains a sound file 1212 and the number of links contained in the item of usage 1216 as well as to what those links pertain, such as a link to a file transfer protocol site 1218 , a link to a commerce site 1220 , a link to a home page 1222 , etc. Furthermore, the association of that item of usage to other items of usage may be represented. In this example, an arrow 1230 including the download time 1232 of the item 1202 as accessed from another item of usage 1240 is shown. Truncated arrows 1234 may also be utilized to denote navigation from this item of usage 1202 to other items of usage.
There are a variety of display options for a persistent usage context of the present invention. For instance, usage may be communicated through the use of representations organized in a spatial relation-mapping scheme that would illustrate the course of usage both two dimensionally and three dimensionally. Additionally, levels of display may be utilized so as to enable a user to choose a high level overall view or more detailed views as the situation warrants. In one embodiment, a high level display may depict a great volume of an organizational map but each representation of an item of usage may have little detailed information. Referring now to FIG. 13, a high level organizational mapping scheme 1300 in an exemplary embodiment of the present invention is shown. In this example, a user initiates a search of the World Wide Web for information relating to motorcycles. A representation displaying that an item of usage involving a search 1302 is displayed, as well as the topic being searched 1304 . After obtaining a search result, a user accesses a web site, in this case a home page 1306 . If a user decided to access a site contained on a favorites list, an arrow 1308 depicting the source of the selection as well as the association of the sites may be shown. After accessing a home page 1310 , the user may access a plurality of sites, two of which 1312 and 1314 lead to one site 1316 . In this way, a user may view organizational associations that may have been difficult to determine under a chronologically based or nested display. A user may then access an additional site 1318 that contains streaming video. Once the user initiates downloading the streaming video a representation 1320 may be communicated indicating that item of usage. After accessing a web site on sidecars 1322 , a user may utilize the history function to jump back to the original search results 1302 . An arrow depicting the utilization of the history function 1324 may be communicated to indicate the usage. A variety of arrows may be utilized to indicate different associations, such as the use of different colors to signify the method of navigation (e.g. the use of a link could be a red line, the use of the back button could be green, the use of a bookmark could be blue, etc.).
The direction of arrows may also be utilized to indicate the progression of the utilization of a system and the association of the representations. For example, a user accessing a home page 1326 may choose to access a link contained in the home page 1326 to advance to another page 1328 . Therefore an arrow depicting the order of access may be used. Additionally a user may wish to access a link contained in one site 1328 so as to access another site 1330 and return to the original site. Therefore a double sided arrow may be utilized to show both accessing another site 1332 and returning to the originating site 1328 . Furthermore, a user may return to a site previously accessed. For example, a user may access a home site 1326 , access another page contained in the site 1328 , go to yet another page 1334 linked to the site 1328 , and then return to the home page 1326 . Therefore, this usage may be shown as a loop in an organization map which would more completely show the associations of the sites than over a traditional chronological map.
Additionally, in an additional embodiment of the present invention, a user may obtain detailed information regarding a representation and corresponding item of usage even in a high level organizational map. Referring again to FIG. 13, a user may view a thread of representations including a home page 1336 and a plurality of web sites and pages linked to the home page 1338 , 1340 and 1342 . If a user wished to determine more information regarding a particular representation, a user may position a cursor 1346 proximally to the representation 1344 to display a pop-up window 1348 . The window 1348 may contain a more detailed representation which contains the representation 1350 , percentage of the information downloaded 1358 , title of the page 1356 and number of links contained in the representation 1352 and 1354 . It may be useful to display the number of links is a symbolic format, such as displaying a group of ten links with a particular symbol 1352 and single links with another symbol 1354 similar to Roman Numerals. It should be apparent that a variety of methods may be used to display information in a representation without departing from the spirit and scope of the present invention.
Referring now to FIG. 14, an exemplary embodiment of the present invention is shown wherein a medium level detail organization scheme is shown. In this example, a search over the World Wide Web is shown. A user may access a search engine, such as Alta Vista® to perform a search for motorcycles. This may be represented by a search representation 1402 , displaying the search engine used 1404 along with the searched 1406 for term 1408 . An arrow 1410 may be utilized to orient the user to the next representation 1414 corresponding to an item of usage and therefore show the association of the representations. It should be apparent that associations may be communicated in a variety of ways, including spatially wherein the distance of the representations from each other is utilized to depict the association, linearly to depict temporal associations, etc. The arrow 1410 may include a number 1412 to further show the order at which the items of usage were utilized. Often, a user may access an initial web page 1416 and then a linked web page 1418 and then access the initial web page again 1416 . Traditionally, a history of this usage would be displayed in a chronological list depicting the initial site, the linked site, and then the initial site again. However, by utilizing the present invention a user may view the association of the sites more readily. Therefore a user accessing a plurality of linked sties and then returning to the initial site 1416 , 1418 , and 1420 may be readily displayed. Additionally, a user accessing a plurality of sites and then returning to one of the sites from the later accessed site may be displayed as a loop by utilizing the organization scheme of the present invention. For example, a user may access a plurality of linked sites, such as a Honda site 1414 , a products site 1416 a speed site 1422 , a new products site 1424 and then return to the original search site 1402 . By displaying the sites as a loop, a user may determine the overall structure and therefore the association of the sites. This may be useful to show the progression of a search, patterns of access in a web site, the overall format of a resource, etc.
Referring now to FIG. 15, an additional exemplary embodiment of the present invention is shown wherein a persistent usage context 1500 may be utilized to reinstall past usage into a web browser. Traditionally, a web browser 1502 may keep a history of web sites accessed 1504 so a user may utilize forward 1508 and backward 1506 buttons to access these previously utilized pages. However, once a user ended the browsing session the ability to access the previous sites with the use of forward 1508 and backward 1506 buttons was lost. A user was forced to utilize a history list that may have saved sites accessed, but were listed in a general order that necessitated accessing each site individually off the list. Therefore, it may be useful to utilize the present invention to load a past usage context into the web browser so a user may again utilize the forward 1508 and backward 1506 buttons as the user had done in the previous session. Furthermore, persistent usage contexts may be stored so as to enable a user to choose a particular context pertaining to a relevant time of usage. For example, a user may utilize a pop-up menu 1512 displayed proximally to a cursor 1510 initiated by a right click of a mouse. Persistent usage contexts may be displayed for a particular time frame, such as a week of usage 1514 and 1516 . However, it may also be useful to enable a user to store and name persistent usage contexts corresponding to user defined criteria. For example, a user may store a particular portion of a browsing session and name the browsing session in a manner to remind the user to what it pertains. It should be apparent that a persistent usage context as previously described herein may be utilized in a wide range of applications, including the utilization of an operating system, network usage, etc. For example, it is now possible to operate an information handling system much like a web browser for applications not traditionally accessed from a web browser, such as word processing, spread sheets, and manipulation of a desktop in Windows®. By utilizing the present invention, a user may load past usage into the operating system much as the previous example for a web browser to enable a user to access previously stored actions.
A Web browser format may also be utilized to access both live and stored past usage, an example of which is shown in FIG. 16 . In this embodiment, a persistent usage context 1600 utilizes parallel navigation bars to access “live” 1602 and “stored” 1604 versions of past usage. For example, as discussed in FIG. 3, usage may be stored on a user's information handling system. However, it may be preferable to also enable a user to access “live” versions of past usage so that the user may access and interact with past points of interest. For instance, a user may view a usage context of a Web browsing session and find a page of particular interest. If that page was not stored on the system, the user could choose to access that page over a live network connection with the use of the “live” buttons 1602 . Another benefit of utilizing separate groups of buttons is that a user may wish to only access stored usage in instances where the live versions are in accessible, e.g. a network connection is not available. For example, if a user was utilizing an information handling system wherein a network connection was not available, the user may choose to use only the stored 1604 buttons to access this usage.
Referring now to FIG. 17, a block diagram of an exemplary information handling system 1700 according to the present invention is shown. In this embodiment, processor 1702 , system controller 1712 , cache 1714 , and data-path chip 1718 are each coupled to host bus 1710 . Processor 1702 is a microprocessor such as a 486-type chip, a Pentium®, Pentium II®, Pentium III® or other suitable microprocessor. Cache 1714 provides high-speed local-memory data (in one embodiment, for example, 512 KB of data) for processor 1702 , and is controlled by system controller 1712 , which loads cache 1714 with data that is expected to be used soon after the data is placed in cache 1712 (i.e., in the near future). Main memory 1716 is coupled between system controller 1714 and data-path chip 1718 , and in one embodiment, provides random-access memory of between 17 MB and 128 MB of data. In one embodiment, main memory 1716 is provided on SIMMS (Single In-line Memory Modules), while in another embodiment, main memory 1716 is provided on DIMMs (Dual In-line Memory Modules), each of which plugs into suitable sockets provided on a motherboard holding many of the other components shown in FIG. 17 . Main memory 1716 includes standard DRAM (Dynamic Random-Access Memory), EDO (Extended Data Out) DRAM, SDRAM (Synchronous DRAM), or other suitable memory technology. System controller 1712 controls PCI (Peripheral Component Interconnect) bus 1720 , a local bus for system 1700 that provides a high-speed data path between processor 1702 and various peripheral devices, such as video, disk, network, etc. Data-path chip 1718 is also controlled by system controller 1712 to assist in routing data between main memory 1716 , host bus 1710 , and PCI bus 1720 .
In one embodiment, PCI bus 1720 provides a 32-bit-wide data path that runs at 33 MHZ. In another embodiment, PCI bus 1720 provides a 64-bit-wide data path that runs at 33 MHZ. In yet other embodiments, PCI bus 1720 provides 32-bit-wide or 64-bit-wide data paths that runs at higher speeds. In one embodiment, PCI bus 1720 provides connectivity to I/O bridge 1722 , graphics controller 1727 , and one or more PCI connectors 1721 , each of which accepts a standard PCI card. In one embodiment, I/O bridge 1722 and graphics controller 1727 are each integrated on the motherboard along with system controller 1712 , in order to avoid a board-connector-board signal-crossing interface and thus provide better speed and reliability. In the embodiment shown, graphics controller 1727 is coupled to a video memory 1728 (that includes memory such as DRAM, EDO DRAM, SDRAM, or VRAM (Video Random-Access Memory)), and drives VGA (Video Graphics Adaptor) port 1729 . VGA port 1729 can connect to VGA-type or SVGA (Super VGA)-type displays. Other input/output (I/O) cards having a PCI interface can be plugged into PCI connectors 1721 .
In one embodiment, I/O bridge 1722 is a chip that provides connection and control to one or more independent IDE connectors 1724 - 1725 , to a USB (Universal Serial Bus) port 1726 , and to ISA (Industry Standard Architecture) bus 1730 . In this embodiment, IDE connector 1724 provides connectivity for up to two standard IDE-type devices such as hard disk drives, CDROM (Compact Disk-Read-Only Memory) drives, DVD (Digital Video Disk) drives, or TBU (Tape-Backup Unit) devices. In one similar embodiment, two IDE connectors 1724 are provided, and each provide the EIDE (Enhanced IDE) architecture. In the embodiment shown, SCSI (Small Computer System Interface) connector 1725 provides connectivity for up to seven or fifteen SCSI-type devices (depending on the version of SCSI supported by the embodiment). In one embodiment, I/O bridge 1722 provides ISA bus 1730 having one or more ISA connectors 1731 (in one embodiment, three connectors are provided). In one embodiment, ISA bus 1030 is coupled to I/O controller 1752 , which in turn provides connections to two serial ports 1754 and 1755 , parallel port 1756 , and FDD (Floppy-Disk Drive) connector 1757 . In one embodiment, FDD connector 1757 is connected to FDD 1758 that receives removable media (floppy diskette) 1759 on which is stored data and/or program code 1760 . In one such embodiment, program code 1760 includes code that controls programmable system 1700 to perform the method described below. In another such embodiment, serial port 1754 is connectable to a computer network such as the Internet, and such network has program code 1760 that controls programmable system 1700 to perform the method described below. In one embodiment, ISA bus 1730 is connected to buffer 1732 , which is connected to X bus 1740 , which provides connections to real-time clock 1742 , keyboard/mouse controller 1744 and keyboard BIOS ROM (Basic Input/Output System Read-Only Memory) 1045 , and to system BIOS ROM 1746 .
FIG. 17 shows one exemplary embodiment of the present invention, however other bus structures and memory arrangements are specifically contemplated.
In one embodiment, I/O bridge 1722 is a chip that provides connection and control to one or more independent IDE connectors 1724 - 1725 , to a USB (Universal Serial Bus) port 1726 , and to ISA (Industry Standard Architecture) bus 1730 . In this embodiment, IDE connector 1724 provides connectivity for up to two standard IDE-type devices such as hard disk drives or CDROM (Compact Disk-Read-Only Memory) drives, and similarly IDE connector 1725 provides connectivity for up to two IDE-type devices. In one such embodiment, IDE connectors 1724 and 1725 each provide the EIDE (Enhanced IDE) architecture. In one embodiment, I/O bridge 1722 provides ISA bus 1730 having one or more ISA connectors 1731 (in one embodiment, three connectors are provided). In one embodiment, ISA bus 1730 is coupled to I/O controller 1752 , which in turn provides connections to two serial ports 1754 and 1755 , parallel port 1756 , and FDD (Floppy-Disk Drive) connector 1757 . In one embodiment, ISA bus 1730 is connected to buffer 1732 , which is connected to X bus 1740 , which provides connections to real-time clock 1742 , keyboard/mouse controller 1744 and keyboard BIOS ROM (Basic Input/Output System Read-Only Memory) 1745 , and to system BIOS ROM 1746 .
Although the invention has been described with a certain degree of particularity, it should be recognized that elements thereof may be altered by persons skilled in the art without departing from the spirit and scope of the invention. One of the embodiments of the invention can be implemented as sets of instructions resident in the main memory 1716 of one or more information handling systems configured generally as described in FIG. 17 . Until required by the information handling system, the set of instructions may be stored in another readable memory device, for example in a hard disk drive or in a removable memory such as an optical disk for utilization in a CD-ROM drive, a floppy disk for utilization in a floppy disk drive, a floptical disk for utilization in a floptical drive, or a personal computer memory card for utilization in a personal computer card slot. Further, the set of instructions can be stored in the memory of another information handling system and transmitted over a local area network or a wide area network, such as the Internet, when desired by the user. Additionally, the instructions may be transmitted over a network in the form of an applet that is interpreted or compiled after transmission to the computer system rather than prior to transmission. One skilled in the art would appreciate that the physical storage of the sets of instructions or applets physically changes the medium upon which it is stored electrically, magnetically, chemically, physically, optically or holographically so that the medium carries computer readable information.
It is believed that the persistent usage context of the present invention and many of its attendant advantages will be understood by the forgoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages, the form herein before described being merely an explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes. | A system and method for generating a persistent usage context is disclosed. In an exemplary embodiment, a method of generating a persistent usage context includes monitoring usage of an information handling system and generating a first representation corresponding to a first item of usage and a second representation corresponding to at least one of the first item of usage and a second item of usage. The first representation and second representation are communicated so as to communicate an association of the first representation to the second representation and to enable a determination of at least one of the prior usage and current usage of an information handling system. | 6 |
BACKGROUND OF THE INVENTION
This invention pertains to shelves and, more particularly, to a display shelf.
Over the years a variety of shelving units, racks and display cases have been build. Many of these shelving units, racks and display cases have been constructed of metal, such as steel, iron, or aluminum. Many other shelving units, racks, and display cases have been fabricated of wood, laminated particle board, and other synthetic materials. Some of the shelving units and display cases have been built with glass windows, glass panels, and/or glass shelves. Shelves constructed of aluminum, laminated particle board, and some synthetic materials have a tendency to warp and bow from use due to loads of the items stored on the shelf.
Conventional shelving units, racks and display cases are often cumbersome and difficult to assemble. Furthermore, conventional shelving units, racks and display cases often requires numerous screws, bolts, nuts, or other fasteners, for assembly which necessitate the use of screwdrivers, wenches, and other tools.
It is, therefore, desirable to provide an improved shelf unit which overcomes most, if not all of the preceding difficulties.
SUMMARY OF THE INVENTION
An improved shelf unit is provided to hold and display items, such as sports items and other articles. The easy-to-assemble shelf unit is especially attractive for use in children's bedroom, recreation rooms, and family rooms to display pictures, trophies and sports memorabilia, such as: trading cards, autograph balls, sports books, etc. Advantageously, the user-friendly shelf unit has a snap-together construction and is preferably molded of impact-resistant plastic to increase longevity and wear as well as to prevent dents, nicks, splinters, rust and other damage. Desirably, the sturdy shelf unit is light weight, economical and reliable.
The novel shelf unit has a special multi-piece shelf assembly with an upper shelf and a lower shelf which snap fit together and are secured to and cantilevered from a wall member, preferably without the use of bolts, screws, nails and other fasteners and preferably without the need for screwdrivers, wrenches, hammers and other tools. To this end, the shelf assembly can have snap-fitting connectors to snap fit and connect the shelves together. One of the shelves can have a set of protuberances and the other shelf can have openings which matingly receive, wedge and engage the complementary protuberances to snap fit and securely couple the shelves. The lower shelf can comprise a platform with a peripheral lip. The upper shelf can comprise an overhanging tray with a peripheral groove which firmly receives and snap fitting engages the peripheral lip of the lower shelf.
In the preferred form, the upper portion of the wall member has a display area which is positioned above the shelf assembly. The lower portion of the wall member can have a sloping support member which engages and helps support the shelf assembly. Preferably, the sloping support member comprises a lower display area which is positioned below the shelf assembly. The shelf unit can also have brackets which extend forwardly of the lower portion of the wall member to provide auxiliary support for the shelf assembly. In the illustrated embodiment, the shelf unit has a series of pegs which provide hanger hooks that are secured to and extend forwardly of the wall member at a location below the shelf assembly to hang items, such as jerseys, caps, jackets, sports equipment, etc. Preferably, the pegs snap or press fit into the wall member. The shelf unit can be produced and made available in different colors with favorite team logos, college insignias, and decals for personalizing, as well as illustrate various sports, such as basketballs, baseball, football, hockey, soccer, etc. The shelf unit completely snaps together; no tools are required. The wall member can have guide slots or openings for mounting on a wall.
The sloping support member, can comprise an elliptical support member which is positioned at the center of the lower portion of the wall member, underneath the shelf assembly. The support member can slope back to the wall member. Advantageously, the sloping support member services a dual function: (1) to support the shelf assembly, and (2) define a recessed area to display a logo, decal, or other sports indicia. The lower display area is also positioned at an angle of inclination to further distinguish viewing of the lower display area from the upper display area.
The upper shelf, which forms the top of the shelf assembly, can be undercut around its periphery to provide a recessed groove and a downwardly extending lip. The lower shelf, which forms the bottom of the shelf assembly, can have a raised bead or lip which provides a peripheral flange that snap fits into the recessed groove of the upper shelf.
In the illustrative embodiment, the lower shelf can have T-shaped interlocking members which engage, insert and glove into complementary T-shaped slots on the front of the wall member in order to help properly align and secure the shelf assembly to the wall member. The lower shelf can also have snaps, such as tongues, which engage and snap into holes in the brackets and support member to help secure the shelf assembly to the brackets and support member.
A more detailed explanation of the invention is provided in the following description and appended claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a shelf unit which provides a sports shelf in accordance with principles of the present invention;
FIG. 2 is a top view of the shelf unit;
FIG. 3 is a front view of the shelf unit;
FIG. 4 is a back view of the shelf unit;
FIG. 5 is a bottom view of the shelf unit;
FIG. 6 is a left side view of the shelf unit;
FIG. 7 is a right side view of the shelf unit; and
FIG. 8 is an enlarged cross-sectional view of a bracket and shelf assembly of the shelf unit taken substantially along line 8--8 of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A sports shelf unit 10 (FIG. 1), which is also sometimes referred to as a Licensed Shelf, sports shelf, sports utility shelf, or a shelving unit, is provided to hold and display items, such as sports items and other articles. The sports shelf unit can be molded of impact-resistant plastic, such as high-impact resin, polyethylene, polypropylene, polyurethane, graphite-impregnated plastic, or other plastic.
The sports shelf unit has an upright plastic wall member 12 (FIG. 1) with a peripheral wall-engaging flange 14 for mounting against a wall. The upright wall member has a pigmented contoured front surface 16 which provides: a front portion with an array of forwardly extending raised portions 18; indented, depressed recessed portions 20, and three dimensional molded-in graphics 22 with colors of a desired sports team, such as for basketball, football, hockey, baseball, soccer, etc.
The back portion 24 (FIG. 4) of the upright wall member has a matrix of plastic flanges 26 which provide a lattice intrastructure to support, strength and rigidify the wall member and shelf unit. The upright wall member also has a substantially horizontal rearwardly extending undercut portion 28 which provides a shelf-receiving groove 30 comprising upper and lower recessed sections. An upper wall portion 32 of the wall member is positioned above the shelf-receiving groove. A lower wall portion 34 of the wall member is positioned below the shelf-receiving groove.
The upper wall portion of the upright wall member has a triangular support section 36 (FIG. 3) and a forwardly extending curved upper display member 38 with upper and lower curved arcuate display sections 40 and 42 and a recessed circular upper display area 44 and section to display sports indicia, such as: sports emblems, sport team logos, team names, illustrations of athletes, portraits of sports figures, and graphical displays of sports subjects.
The lower wall portion of the upright wall member has a downwardly converging bottom section 46 (FIG. 3) and an elliptical central shelf-supporting member 48 which extends and slopes upwardly and forwardly. The elliptical central shelf-supporting member 48 which extends and slopes upwardly and forwardly. The elliptical central shelf-supporting member has a recessed elliptical lower display area 50 and section, which is laterally offset from the circular upper display area 44, to display other sports indicia. The elliptical central shelf-supporting member has an upper raised ledge 52 (FIGS. 3, 4 and 5). The upper raised ledge can have a central inverted T-shaped slot 54 (FIGS. 4 and 5).
The elliptical shelf-supporting member is positioned between plastic shelf-supporting brackets 56 and 58 (FIGS. 1 and 3). The brackets are generally triangular shaped and extend integrally forwardly from the front surface of the lower portion of the wall member. The brackets have inclined sloped front sections 60 (FIGS. 1 and 8) and have upper front corners 62 (FIGS. 3 and 8) with inverted T-shaped bracket-slots 64 (FIG. 8).
The lower wall portion can have a set, series, or array of: peg holes 66 (FIG. 4), finger-receiving apertures 68-71, and elongated openings 72. The peg holes can be circular and positioned between the elliptical shelf-supporting member and the brackets generally about the horizontal centerline of the elliptical shelf-supporting member. The finger-receiving apertures can comprises squares holes, rectangular openings, or slots and can be positioned in proximity to the bottom of the shelf-receiving groove. The laterally outer end finger-receiving apertures 68 and 71 can be positioned laterally outwardly of the brackets. The intermediate finger-receiving apertures 69 and 70 can be positioned laterally inwardly of the brackets in proximity to the elliptical shelf-supporting member. The elongated openings 72 can comprise T-shaped mounting holes and can be located laterally inwardly of the brackets.
A set, series or array of pegs 74 (FIG. 5) are inserted and positioned in the peg holes so as to be securely connected and cantilevered from the lower wall portion of the upright wall member at locations between the brackets and the elliptical shelf-supporting member to hang and support sports items, such as: sport jerseys, caps, hats, baseball gloves, jackets, sports uniforms, sports equipment, sports apparel, and other clothing. Preferably, the pegs comprise plastic pegs with enlarged front end portions providing knobs 76 and hollow tubular body portions 78. The rearward free ends of the pegs, which are opposite the knobs, preferably comprise flexible split ends 80 (FIGS. 4 and 5) which snap fit and wedge in the peg holes.
The sports shelf unit has a plastic shelf assembly 82 (FIGS. 1, 3, and 6-8) which comprises a snap-fitting multi-piece shelf. The shelf assembly has an underlying plastic platform 84 (FIGS. 1, 3, 6 and 7) that provides a lower shelf portion (lower shelf) and has an overhanging overlying plastic try 86 that provides an upper shelf (upper shelf portion).
The bottom 88 (FIGS. 5, 6 and 7) of the lower shelf portion of the shelf assembly is supported and engaged by the top of the shelf-supporting brackets and the upper raised ledge of the elliptical shelf-supporting member. The bottom of the lower shelf portion provides a horizontal base section 90 (FIG. 5) and has a central, upwardly recessed channel 92 (FIG. 5) which diverges rearwardly and provides an intermediate groove and a central recessed section that slidably fits upon, wedges and engages the upper raised ledge of the elliptical shelf-supporting member. The bottom of the lower shelf portion also has upwardly recessed end channels 94 and 96 (FIG. 5) which diverge rearwardly and provide end grooves and recessed bracket-engaging sections that slidably fit upon, wedge and engage the top and upper front corners of the brackets. Rearwardly extending end tongues 98 and 100 (FIG. 5) are positioned in the end grooves (upwardly recessed end channels) to fit within and interlockingly engage the inverted T-shaped bracket-slots of the upper front corners of the brackets so as to snap fit and securely connect the lower shelf portion to the brackets. A central rearwardly extending tongue 102 (FIG. 5) is positioned in the intermediate groove (central upwardly recessed channel) to fit within and interlockingly engage the central inverted T-shaped slot of the raised ledge of the elliptical shelf-supporting member so as to snap fit and securely connect the lower shelf portion to the raised ledge of the shelf-supporting member.
Extending upwardly from the bottom of the lower shelf portion of the shelf assembly is an upright peripheral flange 104 (FIGS. 1, 6 and 7). The upright peripheral flange has an overhanging beaded upper-edge comprising a peripheral lip 106 (FIG. 8). The peripheral lip cooperates with the peripheral flange to provide a peripheral snap-fitting connector 108 (FIG. 8). The upright peripheral lip has a back section 110 (FIG. 5), side sections 112 and 114 which extend forwardly from the back section, and a slightly convex front section 116 which extends between and is integrally connected to the side sections. The back section of the lower shelf portion fits within the lower section of the shelf-receiving groove of the upright wall member. A matrix of flanges which comprise a lattice intrastructure can extend upwardly from the bottom of the lower shelf portion for enhanced strength support, and rigidity.
Pairs of complementary hook-shaped plastic fingers 118-121 (FIG. 4) extend rearwardly and integrally from the back section of the upright peripheral flange of the lower shelf portion. Hooked shaped fingers 118 and 121 are positioned in proximity to the side sections of the upright peripheral lip of the lower shelf portion. Hooked-shaped fingers 119 and 120 are positioned laterally outwardly of the raised ledge of the elliptical shelf-supporting member. Preferably, the hooked-shaped fingers comprise flexible, laterally biased hooked-shaped fingers which diverge forwardly. The fingers are normally biased and are urged laterally outwardly. The fingers can be squeezed, pinched or otherwise moved laterally inwardly toward a rearwardly converging position to interlockingly engage and be positioned within the finger-receiving apertures of the lower wall portion of the upright wall member in order to snap fit, wedge and securely connect the lower shelf portion to the lower wall portion to the upright wall member.
The upper shelf portion of the shelf assembly abuts against, engages, is positioned above, and extend over the lower shelf portion of the shelf assembly. The upper shelf portion has an underside 124 (FIG. 8) and a top 126. The top can comprise a recessed horizontal planar or flat section 128 (FIG. 1) to support and display sports paraphernalia, such as: trophies, sports pictures, autograph sports items, golf balls, baseballs, soccer balls, footballs, basketballs, etc.
The top of the upper shelf section preferably displays the sports paraphernalia at locations between the circular upper display area and the elliptical lower display area. The upper shelf portion also has a raised peripheral edge 130 (FIG. 1) which peripherally surrounds and extends to a height above the recessed horizontal planar, flat section of the upper shelf portion. A curved convex peripheral skirt 132 (FIG. 1) depends and extends integrally downwardly from the raised peripheral edge of the upper shelf portion. The peripheral skirt has: a back 134, sides 136 and 138 which extend forwardly from the back, and a slightly convex front 140 which extends between and is integrally connected to the sides of the skirt. The lower shelf portion has a rearward section 142, which includes the back, that can be securely positioned and wedged in and cantilevered from the upper section of shelf-receiving grove of the upright wall member.
As shown in FIG. 8, the upper shelf portion can have an inner flange 144 which extends and depends integrally downwardly from the underside of the lower shelf portion. The inner flange is spaced laterally inwardly from and cooperates with the peripheral skirt to define a downwardly facing peripheral groove 146 which provides a peripheral socket that securely receives and interlockingly engages the snap-fitting connector (peripheral lip and flange) of the lower shelf portion so as to firmly connect and snap-fit the upper and lower shelf portions together to assembly, form and provide a sturdy shelf assembly.
Among the many advantages of the shelf unit of this invention are:
1. Easy to assemble.
2. Snap together construction.
3. Superior display of sports indicia.
4. Outstanding performance.
5. Ease of decoration with custom colors and personalizing.
6. Prevents splinters, dents and rust.
7. Excellent contoured graphics.
8. Attractive.
9. Strong.
10. Safe.
11. Dependable.
12. User-friendly.
13. Convenient.
14. Durable.
15. Portable.
16. Light-weight.
17. Sturdy.
18. Simple to use.
19. Efficient.
20. Versatile.
21. Economical.
22. Effective.
Although embodiments of the invention have shown and described, it is to be understood that various modifications and substitutions, as well as rearrangements of parts and components, can be made by those skilled in the art without departing from the novel spirit and scope of this invention. | An easy to assemble sports shelf unit with a snap together construction is provided to support and display a variety of items, such as: trophies, awards, sports gear, pictures, and memorabilia. The attractive sports shelf unit has a contoured wall member to which is connected to a special snap-together shelf assembly with upper and lower shelves. The shelf assembly is supported and connected to brackets and an elliptical sloping support member which extends forwardly from the lower portion of the wall member. The elliptical sloping support member provides a lower display area to display logos, team emblems or other sports indicia. The upper portion of the wall member has an offset circular display area to display other sports indicia. Pegs can be connected to lower portion of the wall member, below the shelf assembly, to hang sports gear, jerseys, hats, and other clothing. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority, under 35 U.S.C. §119, of European Patent Application EP 09 180 027.6, filed Dec. 18, 2009; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a lead for painting, which is to be understood as meaning the lead of a pencil, for example of a wooden pencil, and a chalk, which is used for example with a paper or film covering. A pencil equipped with such a lead for painting or a painting chalk serve to produce predominantly flat marks on a substrate such as paper. No special surprise effect appealing predominantly to children is associated therewith. Of somewhat more interest in use are aquarelle leads. Those are formed of a water-soluble lead mass, meaning that a color application produced therewith can be subsequently partially dissolved through treatment with water and be distributed on the substrate using a brush. In that case, however, the original color of the lead is substantially retained. Furthermore, leads are known which are formed of differently colored strands. It is possible to produce multicolored marks, in which case different amounts of the individual colored strands are transferred to the substrate depending on the tilting position and rotational position of the lead, meaning that color nuances or color mixtures can be produced. The invention also relates to a method for painting with a lead.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an alternative lead for painting and a method of painting with a lead, which overcome the hereinafore-mentioned disadvantages of the heretofore-known products and methods of this general type and with which surprising color effects can be produced.
With the foregoing and other objects in view there is provided, in accordance with the invention, a lead for painting. The lead comprises a water-insoluble lead basic mass containing a thermoplastic binder, a water-insoluble colored pigment and a water-soluble dye.
With the objects of the invention in view, there is also provided a method of painting with a lead. The method comprises painting an area of a painting substrate with the lead according to the invention, and then bringing the area of the painting substrate into contact with water using an application device to dissolve one dye present in the lead out of the lead mass and distribute the dye on the painted area.
A lead for painting according to the invention has a water-insoluble lead basic mass in which a water-soluble dye, in particular in solid form, for example as a powder, and a water-insoluble colored pigment, are present. Such a lead for painting permits a completely new painting method with a surprising color effect. Due to the water-insoluble lead basic mass colored with the water-insoluble colored pigment, a mark adhering to the painting substrate is produced when using the lead for painting. The lead basic mass is the mass of a lead which gives it the particular shape, consistency, mechanical and substantially also chemical properties, which form the majority of the lead. A lead basic mass of the present type is thus formed from a water-insoluble binder and just the same admixtures or lead constituents, such as for example inorganic or organic filler particles, lubricants, e.g. based on fatty acid, and other wax-like or fat-like additives. The dyes or dye particles present in the water-insoluble lead basic mass can, due to their solubility in water, be dissolved out of the lead mass e.g. using a brush or a sponge, and be distributed to a greater or lesser extent on the color application, in which case its color impression can be changed overall or restricted to individual area regions. It was unforeseeable that the dyes could be dissolved out of the lead mass although they are embedded in the water-insoluble matrix of the lead basic mass. Upon producing a lead mark on a substrate, the dye particles are presumably partially released so that they can come into contact with the water. The dissolution of the dye is also aided by the fillers present in the lead, which to a certain extent give it a porous consistency that makes it easier for the water to reach the dyes.
With the help of an application device having, for example, a brush or a sponge, it is thus possible to produce regions on the area colored with lead mass which have a coloration that differs from the color of the lead mass and which was previously not visible. These regions do not have to be dried in an involved or time-consuming manner. Instead, the water is absorbed by the painting substrate—generally absorbent substrates such as paper are used—whereupon the dye now colors the substrate. In this way, it is possible to produce diverse long-lasting color effects arising from the color difference between the mark and the substrate colored with the water-soluble dye. The absorption of the aqueous dye solution by the painting substrate is possible because the marks produced with a lead for painting of the present type do not completely cover the painting substrate. Rather, gaps are formed in a lead mark, including those which are not visible to the naked eye, through which the water can reach the painting substrate. In this connection, the fillers present in the lead mass also bring about a certain porosity and thus water permeability.
In principle, the water-insoluble lead mass can be formed of any desired substances provided a lead for painting that can be applied to a painting substrate can be produced therewith. A lead for painting is formed quite generally of a binder which embeds the admixtures present in the lead, such as fillers, the mentioned colored pigments and additives, in a binder matrix. Preference is given to using binders which can be processed without the addition of water together with the other lead constituents e.g. with high-speed mixers or kneaders, to give a mass which can be shaped, for example, in the course of extrusion to give lead strands. The water-soluble dye can then be added without problems to the starting mixture of the lead constituents without the risk of it dissolving and coloring the lead mass. A subsequent treatment with water, or aquarelling, would then barely still bring about the desired color-change effect. Suitable binders are also waxes and fatty acid derivatives and fats, which can likewise be mixed with the other lead constituents without adding water. Finally, in particular, thermoplastic polymers such as polystyrene, styrene-acrylonitrile, polypropylene, acrylic-butadiene-styrene, styrene-acrylonitrile etc. are also suitable. Binders of this type are mixed with the further lead constituents, such as fillers, lubricants and colorants at temperatures at which the binder softens and/or melts. A particularly preferred binder is polyvinylbutyral (PVB). Besides its environmental compatibility and toxicological acceptability, this polymer has the advantage that it already starts to melt at temperatures around 120° C. whereas the aforementioned polymers soften and can be extruded only at temperatures above 180° C. Thermally sensitive constituents, primarily thermally sensitive dyes, can barely still be processed without suffering damage. A lead mass including PVB as a binder, on the other hand, can already be extruded to leads at temperatures around 120° C., a temperature which most water-soluble dyes withstand. Furthermore, it is advantageous that, compared to other thermoplastic polymers, PVB has a greater binding capacity and therefore less PVB is required in order to bind a certain amount of e.g. particulate lead constituents or to produce a lead with a certain diameter. Consequently, using PVB as a binder, it is possible to produce leads with a high fraction of dyes and colored pigments, i.e. with high color intensity and high mechanical stability. Finally, for leads containing PVB as a binder, it is advantageous that they can be applied to a painting substrate in a pleasantly light manner, i.e. with low energy input, to form uniform marks.
Below a fraction of 1% (percentages used at this point and at other points are percentages by weight), it is barely still possible to produce leads with adequate strength and satisfactory marking behavior. At a binder fraction of more than 60% binder, the leads generally exhibit an excessively hard marking behavior. Due to the high binder fraction, the rest remaining for a dye (there are after all other constituents which are also still present, primarily fillers in relatively large amounts) is too low for a significant color effect to be achievable therewith upon treating a color application with water. Consequently, for the leads, a binder range of from 1% to 60% is observed. In the case of PVB which, as stated, need to be present in a considerably lower amount than other thermoplastic binders, that which is stated above applies accordingly with regard to the 1% lower limit. In the case of PVB, its fraction in the lead mass can be lower, meaning that it is preferably limited to 40%.
In order to further optimize the lead consistency and the marking behavior, at least one lubricant in the form of a fatty acid salt, in particular a stearic acid salt, and also further constituents such as waxes and oils, are present in the lead. Preferably, 0.1% to 20% lubricants and 5% to 35% waxes and/or oils are present.
Some water-soluble dyes require a certain pH range. In such cases, according to a further preferred embodiment, the lead includes a pH regulator, which is understood as meaning an acid, a base or an amphoteric agent. Upon treating a lead mark with water, the pH regulator is dissolved out of the lead basic mass together with the dye and changes the pH of the water. By way of example, mention can be made in this case of the dye CI 59040 (solvent green 7), which requires a basic medium. In order to increase the pH, an alkalizing agent is preferably added which exhibits no gas evolution at elevated temperatures, which is the case with sodium phosphate. A carbonate would likewise be suitable as an alkalizing agent, but would cleave off carbon dioxide at the elevated temperatures in the range from 120° C. to at least 200° C., at which a lead mass of the present type is extruded to strands, which would render the leads unusable due to gas inclusions.
Furthermore, there are dyes having a color which is only completely developed as a result of interaction with a substance present in the aqueous medium. This is the case with the aforementioned solvent green 7. Its fluorescent yellow color is only produced more intensely in the presence of a sugar, for example sucrose.
In order to produce the embodiments described below, the lead constituents are mixed intimately in high-speed mixers, twin-screw extruders or the like, which takes place at temperatures at which the thermoplastic binders being used soften and/or melt in such a way that they can be mixed intimately with the other lead constituents. Depending on the binder being used, higher or lower temperatures are required both for the mixing operation and also for the extrusion of lead strands. In the case of polymers such as polystyrene, acrylic-butadiene-styrene, polypropylene, styrene-acrylonitrile and the like, relatively high processing temperatures of more than 200° C. in most cases are required. In the case of the formulations using PVB as a binder, on the other hand, the processing temperatures are much lower, namely in a range around 120° C., which is advantageous in the case of thermally sensitive constituents. After the mixing, either granules are obtained, which are then extruded to give leads, or the lead mass is thoroughly mixed and immediately extruded to give lead strands without the intermediate step of producing granules. Following extrusion, the lead strands are cut to length and encased with a covering e.g. made of wood or—in the case of chalks—provided with a film-like covering.
If a mark on a painting substrate produced with a lead of the present type is treated with water, for example as is the case when aquarelling a mark produced with water-soluble colored leads, the water-soluble dyes are dissolved out. A picture produced on a painting substrate being formed e.g. of paper then has structures given by the lead marks with the base color of the lead mass, where the painting substrate, which has absorbed the colored solution formed by the aquarelling, is differently colored. This gives rise to a variety of configuration possibilities e.g. also as a result of the fact that for one picture, a plurality of colored leads with different colors of the lead basic mass and different water-soluble dyes are used.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a lead for painting and a method for painting with lead, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying examples.
DETAILED DESCRIPTION OF THE INVENTION
Example 1
Lead with gray base color and luminous yellow water-soluble dye, diameter 4.0 mm:
Polyvinylbutyral:
2%
Graphite
35%
Kaolin
44%
Calcium stearate
5%
Stearic acid
5%
Sodium phosphate (Na 3 PO 4 )
1%
Sucrose
5%
CI 59040
3%
The gray basic mass of the lead is achieved by adding graphite powder. The dye CI 59040 being used is dissolved upon treatment of a lead mark with water and/or upon aquarelling. In this case, the sodium phosphate and sucrose are also dissolved out of the mark, as a result of which the dye only then completely develops its luminous yellow color.
Example 2
Lead with gray base color and with two water-soluble dyes, diameter 3.3 mm:
Polyvinylbutyral: CAS 68648-78-2
7.5%
Calcium stearate
12.0%
N,N′-Ethylenebisstearamide CAS 110-30-5
6.0%
Neutral carbon wax
1.8%
Kaolin
30.9%
Castor oil
1.8%
Graphite
30.0%
Dye CI 42090 (blue)
2.0%
Dye CI 19140 (yellow)
8.0%
In the case of this lead too, a gray lead base color is achieved by adding graphite. The dyes dissolved out of a lead mark as a result of aquarelling produce the mixed color green.
Example 3
Lead with a blue-violet base color and with a red, water-soluble dye, diameter 4.0 mm:
Binder styrene-acrylonitrile (SAN)
15%
Wax (e.g. carnauba wax)
10%
Palm oil
2%
Water-insoluble pigment CI 74160 (blue-violet)
6%
Water-soluble dye CI 45410 (red)
20%
Filler talc
47%
The pigment CI 74160 coloring the lead mass blue-violet—a phthalocyanine pigment—is water-insoluble, thus does not dissolve out of the lead basic mass upon aquarelling. As a result of the aquarelling of a lead mark, only the red dye dissolves.
Example 4
Lead with orange-brown base color and with blue, water-soluble dye. Diameter of the lead 3.0 mm:
Binder polyvinylbutyral CAS 68648-78-2
10.0%
Zinc stearate
10.0%
Paraffin wax
8.0%
Kaolin
58.0%
Pigment CI 71105
10.0%
Blue dye CI 42090
4.0%
The orange-brown base color of the lead mass is achieved by the water-insoluble pigment CI 71105.
Example 5
Lead with orange-brown base color and with blue, water-soluble dye. Diameter of the lead 2.5 mm:
Binder polyvinylbutyral CAS 68648-78-2
36.0%
Zinc stearate
12.0%
Paraffin wax
8.0%
Kaolin
28.0%
Pigment CI 71105
12.0%
Blue dye CI 42090
4.0%
The lead corresponds to Example 4 with regard to the colorant being used, but differs from it primarily as a result of a higher content of PVB and a lesser amount of filler.
Example 6
Chalk with orange-brown base color and with blue, water-soluble dye. Diameter of the chalk 8.0 mm:
Binder polyvinylbutyral CAS 68648-78-2
7.0%
Zinc stearate
10.0%
Paraffin wax
9.0%
Kaolin
60.0%
Pigment CI 71105
10.0%
Blue dye CI 42090
4.0%
This is a lead or a chalk with a composition which corresponds substantially to that of Example 4, although the content of PVB is lower.
Example 7
Lead with gray base color and luminous blue water-soluble dye, diameter 4.0 mm:
Polystyrene (Standard PS):
46%
Graphite
35%
Calcium stearate
5%
Stearic acid
5%
Blue dye CI 42090
9%
The gray base color of the lead is achieved by adding graphite. The dye CI 42090 being used is dissolved upon treating a lead mark with water or upon aquarelling. | A lead for painting includes a water-insoluble lead basic mass in which a water-soluble dye is present. A method of painting with a lead is also provided. | 2 |
FIELD OF INVENTION
The present invention relates generally to a safety rail base and post for use on an elevated surface such as a roof for fall prevention. In particular the invention relates to a safety rail base and post for use on or near the edge of various types of elevated surface, such as a roof with a low edge, a low edge with a gravel stop, a parapet wall, and a concrete slab, and for compact storage of said rail base and post.
BACKGROUND
Federal and state regulations, as well as insurance providers, require the use of safety systems to prevent workers from falling from elevated surfaces during construction or maintenance repairs. In certain instances if the proper safety procedures are not followed, governmental organizations such as Occupational Safety and Health Administration (OSHA) can levy fines against companies and building owners due to non-compliance.
The safety systems are important from a regulation standpoint as well as good business practice. Safety systems protect workers from accidental falls and the resulting injuries or death that can occur. Minimizing these types of accidents and the resultant repercussions is important to protect life and limb as well as to reduce liabilities.
Often construction and maintenance/repair companies encounter numerous types of elevated edges, including flat edges, raised edges such as gravel stops, parapet walls, and slab overhangs. These various edges may be encountered on different job sites, a single job site, or even on a single building, and therefore construction companies currently need various types of safety rail bases. For that reason, there are various types of safety rail bases in the prior art; however the construction company must keep the various bases on hand or purchase them when required. This results in large costs and extra storage dedicated to safety equipment. There exists more versatile safety rail bases which are compatible with up to two of the various types of elevated surface edges, thereby decreasing the chance of multiple bases being required on a given jobsite; however construction companies prefer being able to use a single base for three or more of the types of elevated edges that they encounter.
Similarly, construction companies must choose between the available horizontal fall protection barrier types, including, but not limited to, lumber-based rails, metal rails, and cable systems. This is further complicated by the fact that currently there does not exist in the prior art any base and post apparatus that receives multiple types of horizontal barrier types. For example, if a construction company requires a lumber rail for a first job and a cable system for a second job, the company must purchase or rent two entire apparatus systems. Furthermore, not every type of base is produced for every type of horizontal system. This forces construction companies to purchase different brands of railing system, which is undesirable because construction companies often have developed business relations or trust with specific safety product manufacturers.
Lastly, construction sites are often complicated, dangerous places with many hazards and limited space. Therefore it is desirable to store and transport all of the parts of a single base and post (i.e. stanchion) together as a single unit. Keeping the parts in this way minimizes the necessary storage space required and minimizes the risk of losing parts when not in use. Currently there does not exist a parapet clamp base and post which can be stored compactly and as a single unit; that is, the current parapet clamps must be disassembled to store compactly, in which case the parts are separate and can be lost.
SUMMARY OF THE INVENTION
The present invention is a safety rail base and post apparatus 100 for attachment to an elevated surface. The safety rail base and post includes an anchor plate member, a stanchion, a first vertical clamping surface, an adjustable clamp arm having a second clamping surface, configurable to be attached to flat edges, raised edges, parapet walls, and slab overhangs, and at least one bracket operable to receive a lumber rail, metal rail, and tensioned cable.
The safety rail system design provides a temporary railing system for installation on the perimeter of an elevated surface to ensure that when a worker is on the elevated surface that all government regulations and insurance requirements are met for use of proper safety railings.
A further object of the invention is to provide a safety base and post that is configurable to be mounted on flat edges, raised edges, parapet walls, and slab overhangs. By providing a base and post that can be used on any one of these elevated surfaces, a construction company can more readily protect against fall hazards without having to purchase numerous bases and posts.
A further object of the invention is to provide a safety base and post having an adjustable bracket that is configurable to receive a lumber-based horizontal barrier, a metal steel horizontal barrier, and a tensioned cable. By providing a base and post having an adjustable bracket configurable to receive any of these types of horizontal barriers, a construction company can more easily adapt its safety plan to the requirements of the job site and limit the amount of safety equipment required.
A further object of the invention is to provide a safety base and post configurable to be compactly stored as a single unit. This will enable construction companies to reduce consumption of valuable space on job sites, reduce the number of hazards presented by a stored safety unit, and reduce the chance of parts becoming lost or misplaced due to disjointed storage.
Other objects of the present invention relating to an adaptable safety base and post configurable for numerous elevated edges and horizontal barrier types will become readily apparent upon reading the following detailed description in conjunction with the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate embodiments of the invention and are for illustration by way of example and not limitations.
FIG. 1 illustrates a top perspective view of a safety base and post apparatus and horizontal barriers system installed on the perimeter of a building, in accordance with an embodiment of the invention;
FIG. 2 illustrates a top perspective of a safety base and post installed on a flat edge, in accordance with an embodiment of the invention;
FIG. 3 illustrates a top perspective of a safety base and post installed on a gravel stop edge, in accordance with an embodiment of the invention;
FIG. 4 illustrates a top perspective of a safety base and post installed on a parapet wall, in accordance with an embodiment of the invention;
FIG. 5 illustrates a top perspective of a safety base and post installed on a slab overhang, in accordance with an embodiment of the invention;
FIG. 6 illustrates a top perspective of a safety base and post in a stored configuration, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is to a safety base and post apparatus as shown in FIGS. 1-6 . Specifically, the invention is an adaptable safety rail and base apparatus 100 configurable to be installed on elevated surfaces such as that of a building 102 ( FIG. 1 ), including flat edges 104 ( FIG. 2 ), over raised edges 106 ( FIG. 3 ), parapet walls 108 ( FIG. 4 ), and slab overhangs 110 ( FIG. 5 ), as well as being configurable to be compactly stored as a single unit ( FIG. 6 ).
The safety base and post apparatus is shown in multiple views in FIGS. 1-6 and the invention presents an adaptable base and post, when used in conjunction with horizontal safety barriers provides a fall restraint on or near the edge of an elevated surface to aide in the safety of workers. As detailed in FIG. 2 , the safety base and post apparatus 100 includes a base 10 and stanchion 12 . The base 10 includes a generally vertical mounting surface 14 and generally horizontal mounting surface 16 . The mounting surface 14 is preferably precisely vertical and the horizontal mounting surface 16 precisely horizontal, so as to form a right angle between the two surfaces; however in another embodiment it may be beneficial to provide surfaces 14 , 16 having a relative angle as low as forty-five degrees and as high as one hundred and thirty-five degrees. The surfaces 14 , 16 include at least one hole 18 for receiving at least one fastener 20 . Preferably the surfaces 14 , 16 include a plurality of holes 18 for receiving a plurality of fasteners 20 . The fastener 20 can be a screw, lag bolt, nail, rivet, masonry anchor, or any other anchoring product used in the industry and designed for the desired building structure to attach the base 10 to the elevated surface 102 . The fastener 20 is generally a roofing screw, concrete screw, or any fastener designed to structurally mount a railing system to a structure. The vertical mounting surface 14 and horizontal mounting surface 16 enables the apparatus to be mounted to a flat edge 104 , i.e. a flat edge configuration. The base 10 is made of any material used in the industry to fabricated safety rail systems, including but not limited to metal, such as steel and aluminum, wood, plastic, other man-made materials, as well as any material approved for use to ensure the safety structure meets OSHA standards. In one embodiment, the base 10 is made of steel with a thickness of 1/16″ to 5/16″ of an inch. The base 10 itself and the base 10 and stanchion 12 together may be formed out of a single piece of material, or joined out of multiple pieces through manufactured processes such as welding, bonding, or fastening. In one embodiment the stanchion 12 is generally elongated and straight; however, in certain instances it may be preferable for the stanchion 12 to have at least one bend so as to create an offset between the distal ends of the stanchion 12 . The stanchion further is preferably tubular and even more preferably a round tube.
In another embodiment of the invention, and as shown in FIG. 3 , the base 10 further includes a space 22 intermediate the mounting surfaces 14 , 16 configured to accept a raised edge 106 . This configuration enables the apparatus 100 to be mounted to surfaces 102 having a raised edge 106 . Raised edges such as gravel stops are generally at most one inch high and one inch thick; therefore the space 22 is preferably no larger than one inch by one inch in size.
In another embodiment of the invention, and as shown in FIG. 4 , the safety base and post apparatus 100 is further configured to clamp onto a parapet wall 108 . In this embodiment, the apparatus 100 further includes a first vertical clamping surface 24 . In a particular embodiment, the first vertical clamping surface 24 is attached preferably to the stanchion 12 by an adjuster 26 . Alternatively the adjuster 26 may attach the clamping surface 24 to the base 10 . The adjuster 26 is preferably adjustable, thereby enabling a user to alter the position or spacing of the first vertical clamping surface 24 . The apparatus 100 further includes an intermediate opening 28 for at least partially receiving an adjustable clamp arm 30 . In this embodiment the stanchion 12 and adjustable clamp arm 30 are preferably least partially tubular, and preferably made of round tube. The adjustable clamp arm 30 is generally L-shaped and includes a second clamping surface 32 near its distal end. An adjuster 34 , preferably a screw-type adjuster, connects the second clamping surface 32 to the adjustable clamp arm 30 . In this way, the second clamping surface 32 can be adjusted in relation to the adjustable clamp arm 30 . A fastener 36 secures the adjustable clamp arm 30 in the intermediate opening 28 . The fastener 36 is preferably a screw-type fastener but can be a clamp, latch, pin, or other fastener known in the art to fasten two members together. In this configuration, the first vertical clamping surface 24 and second clamping surface 32 are vertically parallel and operable to cooperatively clamp to a parapet wall 108 . Further inserting the adjustable clamp arm 30 into the intermediate opening 28 , tightening the fastener 36 and then tightening the adjusters 26 and 34 create a secure clamping of the parapet wall 108 . Parapet walls generally vary in thickness from four inches to twenty-four inches, so the adjustable clamp arm 30 and adjusters 26 and 34 are operable to adjust the clamping surfaces 24 and 32 between four inches and twenty-four inches apart. The adjustable clamp arm 30 is made of any material used in the industry to fabricated safety rail systems.
In another embodiment of the invention, shown in FIG. 5 , the apparatus 100 can be mounted to a slab overhang 110 . In this embodiment, the apparatus further includes a lower opening 38 . The lower opening 38 is preferably located distally on the bottom end of the stanchion 12 . In this embodiment the stanchion 12 and adjustable clamp arm 30 are preferably tubular. In this configuration the adjustable clamp arm 30 is at least partially inserted into the lower opening 38 . The stanchion 12 typically includes an auxiliary opening 40 near the lower opening 38 . The adjustable clamp arm 30 includes a corresponding fastener opening 42 . When the auxiliary opening 40 and fastener opening 42 are aligned, a fastener 44 , typically a through-pin, is inserted through the auxiliary opening 40 and fastener opening 42 , so as to secure the adjustable clamp arm 30 at least partially in the lower opening 38 . In this configuration, the second clamping surface 32 and horizontal mounting surface 16 are horizontally parallel and thus can be moved adjacent to the bottom and top of a slab overhang 110 , respectively. Tightening the adjuster 34 creates a secure clamping of the slab overhang. Slab overhangs are generally between two inches and twelve inches thick. Therefore the adjustable clamp arm 30 and adjuster 34 are operable to adjust the vertical offset between the clamping surface 32 and horizontal mounting surface 16 from between two inches and twelve inches.
In another embodiment of the invention, as shown in FIG. 6 , the apparatus 100 can be compactly stored as a single unit. In this embodiment the apparatus 100 further includes an upper opening 46 . In this embodiment the stanchion 12 and adjustable clamp arm 30 are preferably tubular. The upper opening 46 is preferably located distally on the top end of the stanchion 12 . The adjustable clamp arm 30 is at least partially inserted into the upper opening 46 . A storage opening 48 is located near the upper opening 48 . When the storage opening 48 and fastener opening 42 are aligned, the fastener 44 is inserted through the storage opening 48 and fastener opening 42 , thereby securing the adjustable clamp arm 30 in a storage configuration.
Turning again to FIGS. 2-4 , the safety base and post apparatus 100 is operable to receive various horizontal barriers, including lumber type horizontal barriers 112 ( FIG. 2 ), metal rail type horizontal barriers 114 ( FIG. 3 ), and tensioned cable type horizontal barriers 116 ( FIG. 4 ). The apparatus 100 generally includes at least one and preferably two brackets 50 . More particularly, and as shown in FIG. 2 , the bracket 50 can be positioned at various heights on the stanchion 12 . The bracket 50 can also be positioned at various rotational angles, to be used on various architectural geometries such as corners and circular buildings, or for utilizing the other horizontal barriers such as metal rail and tensioned cable type barriers, detailed below, or for utilizing the various mounting and clamping configurations, as described above. A fastener 52 , preferably a screw-type fastener, can be tightened to secure the bracket 50 at a specified height on the stanchion 12 . The bracket 50 includes a guide 54 having a space 56 for receiving a lumber-based horizontal barrier 112 . The guide 54 further includes at least one hole 58 for receiving a fastener 60 to secure the barrier 112 to the guide 54 . Typical fasteners include but are not limited to screws, nails, pins, or other suitable fastener.
Similarly, and as shown in FIG. 3 , the bracket 50 generally includes a pin 62 for receiving a metal rail type horizontal barrier 114 . In a particular embodiment, the pin 62 and guide 54 are oppositely positioned on the bracket 50 . To switch between utilizing the guide 54 and the pin 62 , the bracket 50 is simply rotated 180 degrees and secured by tightening the fastener 60 .
Similarly, the bracket 50 generally includes at least one hook 64 for receiving a tensioned cable 116 . Preferably, the bracket 50 includes two oppositely facing hooks 64 offset from one another, which improves the ease with which a cable 116 is attached to the apparatus 100 without becoming unhooked.
Thus, there has been described a safety base and post assembly 100 . It is apparent to those skilled in the art, however, that many changes, variations, modifications, other uses, and applications are possible, and also such changes, variations, modifications, other uses, and applications which do not depart from the spirit and scope of the invention are deemed covered by the invention, which is limited only by the claims which follow. | A safety apparatus for use on an elevated surface, for providing fall protection for multiple elevated surface configurations, so as to adaptably secure a safe work environment, the safety apparatus comprising a base member, wherein the base member includes a vertical mounting surface and a horizontal mounting surface, a stanchion, a first vertical clamping surface near the base of the stanchion, an adjustable clamp arm having a second clamping surface, wherein the clamp arm is operable to be attached to the stanchion in a horizontal slab clamp configuration, and at least one bracket operable to receive a horizontal fall protection barrier. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to pyrimidinyl-pyrazole compounds, compositions and medicaments thereof, as well as processes for the preparation and use of such compounds, compositions and medicaments. Such pyrimidinyl-pyrazole compounds are potentially useful in the treatment of diseases associated with Aurora kinase activity.
[0002] Protein kinases catalyze the phosphorylation of hydroxylic amino acid side chains in proteins by the transfer of the γ-phosphate of ATP-Mg 2+ to form a mono-phosphate ester of serine, threonine or tyrosine. Studies have shown that protein kinases are key regulators of many cell functions, including signal transduction, transcriptional regulation, cell motility and cell division. Several oncogenes have also been shown to encode protein kinases, suggesting that kinases may play a role in oncogenesis.
[0003] The protein kinase family of enzymes is typically classified into two main subfamilies: protein tyrosine kinases and protein serine/threonine kinases, based on the amino acid residue they phosphorylate. Aberrant protein serine/threonine kinase activity has been implicated or is suspected in a number of pathologies such as rheumatoid arthritis, psoriasis, septic shock, bone loss, cancers and other proliferative diseases. Tyrosine kinases play an equally important role in cell regulation. These kinases include several receptors for molecules such as growth factors and hormones, including epidermal growth factor receptor, insulin receptor and platelet derived growth factor receptor. Studies have indicated that many tyrosine kinases are transmembrane proteins with their receptor domains located on the outside of the cell and their kinase domains on the inside. Accordingly, both kinase subfamilies and their signal transduction pathways are important targets for drug design.
[0004] Since its discovery in 1997, the mammalian Aurora family of serine/threonine kinases has been closely linked to tumorigenesis. The three known mammalian family members, Aurora-A (“2”), B (“1”) and C (“3”), are highly homologous proteins responsible for chromosome segregation, mitotic spindle function and cytokinesis. Aurora expression is low or undetectable in resting cells, with expression and activity peaking during the G2 and mitotic phases in cycling cells. In mammalian cells, proposed substrates for the Aurora A and B kinases include histone H3, CENP-A, myosin II regulatory light chain, protein phosphatase 1, TPX2, INCENP, p53 and survivin, many of which are required for cell division.
[0005] The Aurora kinases have been reported to be over-expressed in a wide range of human tumors. Elevated expression of Aurora-A has been detected in colorectal, ovarian and pancreatic cancers, and in invasive duct adenocarcinomas of the breast. High levels of Aurora-A have also been reported in renal, cervical, neuroblastoma, melanoma, lymphoma, pancreatic and prostate tumor cell lines. Amplification/over-expression of Aurora-A is observed in human bladder cancers, and amplification of Aurora-A is associated with aneuploidy and aggressive clinical behavior. Moreover, amplification of the Aurora-A locus (20q13) correlates with poor prognosis for patients with node-negative breast cancer. In addition, an allelic variant, isoleucine at amino acid position 31, is reported to be a low-penetrance tumor-susceptibility gene. This variant displays greater transforming potential than the phenylalanine-31 variant and is associated with increased risk for advanced and metastatic disease. Like Aurora A, Aurora-B is also highly expressed in multiple human tumor cell lines, including leukemic cells. Levels of Aurora-B increase as a function of Duke's stage in primary colorectal cancers. Aurora-C, which is normally only found in germ cells, is also over-expressed in a high percentage of primary colorectal cancers and in a variety of tumor cell lines, including cervical adenocarinoma and breast carcinoma cells.
[0006] The prior art supports the hypothesis that in vitro an inhibitor of Aurora kinase activity would disrupt mitosis causing cell cycle defects and eventual cell death. Therefore, in vivo, an Aurora kinase inhibitor should slow tumor growth and induce regression. For example, Hauf et al. describe an Aurora B inhibitor, Hesperadin, that causes defects in chromosomal segregation and a block in cytokinesis, thereby resulting in polyploidy [Hauf, S et al. JCB 161(2), 281-294 (2003)]. Ditchfield et al. have described an equipotent inhibitor of Aurora A and B (ZM447439) that causes defects in chromosome alignment, chromosome segregation and cytokinesis [Ditchfield, C. et al., JCB 161(2), 267-280 (2003)]. Furthermore, the authors show that proliferating cells, but not cell-cycle arrested cells, are sensitive to the inhibitor. Efficacy of a potent Aurora A and B inhibitor in mouse and rat xenograft models was recently reported [Harrington, E. A. et al., Nature Medicine 10(3), 262-267, (2004)]. These results demonstrate that inhibition of Aurora kinases can provide a therapeutic window for the treatment of proliferative disorders such as cancer (see Nature, Cancer Reviews, Vol. 4, p927-936, December 2004, for a review by N. Keen and S. Taylor, which outlines the therapeutic potential of Aurora kinase inhibitors for the treatment of cancer).
[0007] In view of the teachings of the art, there is a need for the discovery of kinase activity inhibitors, in particular, compounds that inhibit the activity of Aurora kinases.
SUMMARY OF THE INVENTION
[0008] In a first aspect, the present invention is a compound of formula (I):
[0000]
[0000] or a pharmaceutically acceptable salt thereof, or a solvate thereof, or a combination thereof, wherein:
R 1 represents phenyl, substituted phenyl, heteroaryl, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, or —NR 7 R 8 ;
R 2 and R 3 each independently represent H, halo, C 1 -C 3 alkyl, or —O—C 1 -C 3 alkyl;
R 4 , a substituent for one of the nitrogen atoms of the pyrazole ring, represents H, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, —C(O)C 1 -C 6 alkyl, —C(O)-substituted C 1 -C 6 alkyl, —C(O)NR 7 R 8 , —S(O) 2 —C 1 -C 6 alkyl, —S(O) 2 —C 3 -C 6 cycloalkyl, or —C(O)NH—C 1 -C 6 alkyl;
R 5 , R 5′ , and R 6 each independently represent H, halo, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, —NH—C(O)-substituted C 1 -C 6 alkyl, —NR 7 R 8 , —O—C 1 -C 6 alkyl, —O-substituted C 1 -C 6 alkyl or hydroxyl; and
R 7 and R 8 each independently represent H, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, phenyl, substituted phenyl or heteroaryl, or form, together with the nitrogen atom to which they are attached, a substituent selected from the group consisting of pyrrolidinyl, piperidinyl, morpholinyl, piperazinyl, 4-(C 1 -C 6 alkyl)-piperazin-1-yl, and 4-(hydroxy-C 2 -C 6 alkyl)-piperazin-1-yl.
[0009] In a second aspect, the present invention is a composition comprising the compound represented by Formula (I), or a salt thereof, or a solvate thereof, or a combination thereof, in admixture with one or more pharmaceutically acceptable excipients.
[0010] In a third aspect, the present invention is a method for treating a disease of cell proliferation comprising administering to a patient in need thereof a compound represented by Formula I or a salt thereof, or a solvate thereof, or a combination thereof.
[0011] In a fourth aspect the present invention is a method comprising the step of administering to a patient in need thereof an effective amount of a composition comprising (a) the compound represented by Formula (I), or a salt thereof, or a solvate thereof, or a combination thereof, and (b) at least one pharmaceutically acceptable excipient.
[0012] The present invention addresses a need in the art by providing a class of pyrimidinyl-pyrazoles inhibitors of Aurora kinase activity. Such compounds are useful in the treatment of disorders associated with inappropriate Aurora kinase family activity.
DETAILED DESCRIPTION OF THE INVENTION
[0013] In a first aspect, the present invention relates to a compound of formula (I):
[0000]
[0000] or a pharmaceutically acceptable salt thereof, or a solvate thereof, or a combination thereof, wherein:
R 1 represents phenyl, substituted phenyl, heteroaryl, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, or —NR 7 R 8 ;
R 2 and R 3 each independently represent H, halo, C 1 -C 3 alkyl, or —O—C 1 -C 3 alkyl;
R 4 , a substituent for one of the nitrogen atoms of the pyrazole ring, represents H, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, —C(O)C 1 -C 6 alkyl, —C(O)-substituted C 1 -C 6 alkyl, —C(O)NR 7 R 8 , —S(O) 2 —C 1 -C 6 alkyl, —S(O) 2 —C 3 -C 6 cycloalkyl, or —C(O)NH—C 1 -C 6 alkyl;
R 5 , R 5′ , and R 6 each independently represent H, halo, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, —NH—C(O)-substituted C 1 -C 6 alkyl, —NR 7 R 8 , —O—C 1 -C 6 alkyl, —O-substituted C 1 -C 6 alkyl or hydroxyl; and
R 7 and R 8 each independently represent H, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, phenyl, substituted phenyl or heteroaryl, or form, together with the nitrogen atom to which they are attached, a substituent selected from the group consisting of pyrrolidinyl, piperidinyl, morpholinyl, piperazinyl, 4-(C 1 -C 6 alkyl)-piperazin-1-yl, and 4-(hydroxy-C 2 -C 6 alkyl)-piperazin-1-yl.
[0014] As used herein, substituted phenyl refers to phenyl substituted with up to 3 groups selected from C 1 -C 6 -alkyl, halo, cyano, —O—C 1 -C 6 -alkyl, nitro, and hydroxyl.
[0015] As used herein, substituted C 1 -C 6 alkyl refers to a C 1 -C 6 alkyl group substituted with hydroxyl, —O—C 1 -C 6 alkyl, —CO 2 R 7 , —NR 7 R 8 , —C(O)NR 7 R 8 , —S(O) 2 —C 1 -C 6 alkyl, —S(O) x NR 7 R 8 (where x is 0, 1, or 2); or up to 3 halo groups. An example of —NH—C(O)-substituted C 1 -C 6 alkyl is (dimethylamino)methylcarbonylamino. Examples of substituted C 1 -C 6 alkyl-NR 7 R 8 include —(CH 2 ) n -morpholinyl, —(CH 2 ) n -piperidinyl, —(CH 2 ) n -[4-(C 1 -C 6 alkyl)-piperazin-1-yl], or —(CH 2 ) n -[4-(hydroxy-C 1 -C 6 alkyl)-piperazin-1-yl], where n is an integer from 1 to 6.
[0016] As used herein, heteroaryl refers to furanyl, thienyl, pyridinyl, pyrazolyl, tetrazolyl, oxazolyl, isoxazolyl, imidazolyl and pyrrolyl.
[0017] It will be understood that compounds of formula (I) may exist in alternative tautomeric form, for example when R 4 represents a non-hydrogen substituent on the nitrogen atom in the 1-position.
[0018] Representative C 1 -C 6 alkyl groups include methyl, ethyl, n-propyl, isopropyl, isobutyl, n-butyl, t-butyl, n-pentyl, and n-hexyl. Representative halo groups include fluoro, chloro, bromo and iodo groups. Examples of suitable O—C 1 -C 6 alkyl groups include methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, and t-butoxy.
[0019] Representative C 3 -C 6 -cycloalkyl groups include cyclopropyl, cyclopentyl, and cyclohexyl groups, which may optionally be substituted with one or more C 1 -C 6 alkyl groups.
[0020] As used herein, pharmaceutically acceptable refers to those compounds, materials, compositions, and dosage forms which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of human beings and animals without excessive toxicity, irritation, or other problem or complication, commensurate with a reasonable benefit/risk ratio. The skilled artisan will appreciate that pharmaceutically acceptable salts of the compounds according to Formula (I) may be prepared. These pharmaceutically acceptable salts may be prepared in situ during the final isolation and purification of the compound, or by separately reacting the purified compound in its free acid or free base form with a suitable base or acid, respectively.
[0021] In certain embodiments, compounds according to Formula (I) may contain an acidic functional group and are, therefore, capable of forming pharmaceutically acceptable base addition salts by treatment with a suitable base. Examples of such bases include (a) hydroxides, carbonates, and bicarbonates of sodium, potassium, lithium, calcium, magnesium, aluminum, and zinc; and (b) primary, secondary, and tertiary amines including aliphatic amines, aromatic amines, aliphatic diamines, and hydroxy alkylamines such as methylamine, ethylamine, 2-hydroxyethylamine, diethylamine, triethylamine, ethylenediamine, ethanolamine, diethanolamine, and cyclohexylamine.
[0022] In certain embodiments, compounds according to Formula (I) may contain a basic functional group and are therefore capable of forming pharmaceutically acceptable acid addition salts by treatment with a suitable acid. Suitable acids include pharmaceutically acceptable inorganic acids and organic acids. Representative-pharmaceutically acceptable acids include hydrogen chloride, hydrogen bromide, nitric acid, sulfuric acid, sulfonic acid, phosphoric acid, acetic acid, hydroxyacetic acid, phenylacetic acid, propionic acid, butyric acid, valeric acid, maleic acid, acrylic acid, fumaric acid, malic acid, malonic acid, tartaric acid, citric acid, salicylic acid, benzoic acid, tannic acid, formic acid, stearic acid, lactic acid, ascorbic acid, p-toluenesulfonic acid, oleic acid, lauric acid, and the like.
[0023] As used herein, the term “a compound of Formula (I)” or “the compound of Formula (I)” refers to one or more compounds according to Formula (I). The compound of Formula (I) may exist in solid or liquid form. In the solid state, it may exist in crystalline or noncrystalline form, or as a mixture thereof. The skilled artisan will appreciate that pharmaceutically acceptable solvates may be formed for crystalline compounds wherein solvent molecules are incorporated into the crystalline lattice during crystallization. Solvates may involve non-aqueous solvents such as, but not limited to, ethanol, isopropanol, DMSO, acetic acid, ethanolamine, and ethyl acetate, or they may involve water as the solvent that is incorporated into the crystalline lattice. Solvates wherein water is the solvent incorporated into the crystalline lattice are typically referred to as “hydrates.” Hydrates include stoichiometric hydrates as well as compositions containing variable amounts of water. The invention includes all such solvates.
[0024] Compounds of formula (I) may be prepared using the methods described below. In all of the schemes described below, it is understood that protecting groups may be employed where necessary in accordance with general principles known to those of skill in the art, for example, see T. W. Green and P. G. M. Wuts (1991) Protecting Groups in Organic Synthesis, John Wiley & Sons. These groups may be removed at a convenient stage of the compound synthesis using methods known to those of skill in the art. The selection of processes as well as the reaction conditions and order of their execution shall be consistent with the preparation of compounds of formula (I).
[0025] Compounds of formula (I) may be conveniently prepared by the methods outlined in Scheme 1 below. Compounds of formula (II) and (III) are commercially available or may be synthesized using techniques conventional in the art. R 9 represents NO 2 , a protected amino group (such as, but not limited to, tert-butoxycarbonylamino, cyclopropylcarbonylamino and benzoylamino group) or a group readily converted to an amino group or a protected amino group (such as a halogen or a triflate group). R 10 and R 11 independently represent alkyl or aryl groups. Reaction of a compound of formula (II) with a compound of formula (III) yields a compound of formula (IV). This reaction may be performed using a base such as lithium hexamethyldisilazide, in an inert solvent, such as tetrahydrofuran, at low temperature, followed by quenching with an appropriate acid, such as aqueous hydrochloric acid.
[0026] The compound of formula (IV) may then be converted to a compound of formula (V) by treatment with a dialkyl acetal of dimethylformamide or an equivalent chemical entity, followed by reaction with aqueous hydrazine in a solvent such as ethanol. The compound of formula (V) may then be oxidized to a compound of formula (VI), which constitutes a sulfoxide when m=1 or a sulfone when m=2, using an oxidant such as Oxone® or meta-chloroperbenzoic acid in an appropriate solvent such as methylene chloride, tetrahydrofuran, water or methanol. The compound of formula (VI) may then be reacted with R 4 X (wherein X represents a leaving group such as, but not restricted to, halide, trifluorosulfonate, mesylate or tosylate) to afford a compound of formula (VII). This reaction may be performed in the presence of base, such as potassium t-butoxide or potassium carbonate, in a solvent, such as tetrahydrofuran, acetone or dimethylformamide, under an inert atmosphere.
[0027] Depending on the nature of the alkylating agent and the reaction conditions, the compound of formula (VII) may be isolated as a pure regioisomer or a mixture of the two possible regioisomers (where the R 4 group is attached to one of the N atoms of the pyrazole ring). In the case where a mixture of regioisomers is obtained, these isomers may be separated by physical methods (such as crystallization or chromatographic methods) at this stage or any other later stage in the synthetic scheme.
[0028] The compound of formula (VII) may then be converted to a compound of formula (IX) by reaction with the appropriate aniline of formula (VIII), which is commercially available or may be synthesized using techniques conventional in the art. This conversion may be achieved under acidic conditions (such as, but not restricted to, heating with trifluoroacetic acid or aqueous hydrochloric acid in a solvent such as isopropanol or n-butanol) or basic conditions (such as, but not restricted to, treatment with sodium hexamethyldisilazide in tetrahydrofuran at low temperature).
[0029] In the case where R 9 is chosen as the desired R 1 C(O)NH— group, the compound of formula (IX) is indeed identical to the desired final compound of formula (I). If that is not the case, the compound of formula (IX) may be converted to a compound of formula (X), where the unmasking of the amino group is performed using methods consistent with the chemical nature of group R 9 . In the case where R 9 is a nitro group, unmasking of the amino group may be achieved by standard reductive methods, such as, but not restricted to, hydrogenation over a reactive catalyst (such as platinum dioxide, platinum on carbon, or palladium on carbon) or reaction with stannous chloride or iron in the presence of acid. In the case where R 9 is the tert-butylcarbonylamino group, unmasking of the amino group may be achieved by acid treatment, such as, but not restricted to, trifluoacetic acid in methylene chloride, trifluoacetic acid in water or aqueous hydrochloric acid. Those skilled in the art should recognize that other R 9 groups may be used in this preparation, and their deprotection or conversion to the amino group should be performed according to their specific chemical nature.
[0030] The desired compound (I) may then be prepared by converting the compound of formula (X) to an amide or a urea. Amide formation may be achieved by treating the compound of formula (X) with acylating reagents such as, but are not restricted to, acyl chlorides, acid anhydrides and carboxylic acids activated by a coupling agent such as, but not limited to, HATU, HBTU or TBTU. Urea formation may be achieved, for example, (a) by treatment of the compound of formula (X) with an isocyanate in an inert solvent, or (b) by treatment of the compound of formula (X) with phosgene or equivalent in an inert solvent, followed by incubation with the amine of interest, or (c) by treatment of the amine of interest with phosgene or equivalent in an inert solvent, followed by incubation with the compound of formula (X).
[0000]
[0031] The compound of formula (V) may be also converted to the compound of formula (IX) according to the two alternative reaction sequences outlined in Scheme 2. The compound of formula (V) may be treated with strong aqueous acid, such as concentrated HCl, to yield the compound of formula (XI), which may then be converted to the compound of formula (XII) by treatment with a chlorinating agent, such as phosphorous oxychloride. The compound of formula (XII) may then be reacted with the aniline of formula (VIII), which is commercially available or may be synthesized using techniques conventional in the art. This conversion may be achieved under acidic conditions (such as, but not restricted to, heating with trifluoroacetic acid or aqueous hydrochloric acid in a solvent such as isopropanol or n-butanol) or basic conditions (such as, but not restricted to, treatment with sodium hexamethyldisilazide in tetrahydrofuran at low temperature). The compound of formula (XIII) may then be reacted with R 4 X (wherein X represents a leaving group such as, but not restricted to, halide, trifluorosulfonate, mesylate or tosylate) to afford a compound of formula (IX). This reaction may be performed in the presence of base, such as potassium t-butoxide or potassium carbonate, in a solvent, such as tetrahydrofuran, acetone or dimethylformamide, under an inert atmosphere. Alternatively, the compound of formula (V) may be alkylated with R 4 X to generate the compound of formula (XIV). Treatment of the compound of formula (XIV) with a strong aqueous acid, such as concentrated HCl, should yield the compound of formula (XV), which can be converted to the chloride (XVI) by treatment with phosphorous oxychloride. The compound of formula (XVI) may then be reacted with the aniline (VIII) under conditions described above, generating the compound of formula (IX).
[0000]
[0032] Alternatively, the compound of formula (VII) may be prepared by the route outlined on Scheme 3, where R 4 is attached to the specified N atom of the pyrazole ring shown in that Scheme. Treatment of the compound of formula (IV) with the hydrazine R 4 NHNH 2 (which is commercially available or may be synthesized using techniques conventional in the art) yields a compound of formula (XVII). The compound of formula (XVII) may then be reacted with the dialkyl acetal of dimethylformamide or equivalent chemical entity to generate a compound of formula (XVIII). Treatment of the compound of formula (XVIII) with an oxidant, such as, but not limited to, Oxone® or meta-chloroperbenzoic acid, in an inert solvent such as methylene chloride, affords the compound of formula (VII) where the R 4 group is attached to the specified N atom of the pyrazole ring. The compound of formula (VII) may then be converted to the compound of formula (I), where the R 4 group is attached to the specified N atom of the pyrazole ring, according to the procedure outlined on Scheme 1.
[0000]
[0033] Alternatively, the compound of formula (IX) may be generated according to the reactions outlined in Scheme 4. The compound of formula (II) may be reacted with the compound of formula (XIX), which is commercially available or may be synthesized using techniques conventional in the art, to afford a compound of formula (XX). The compound of formula (XX) may then be converted to a compound of formula (XXI) by reaction with the appropriate aniline of formula (VIII), which is commercially available or may be synthesized using techniques conventional in the art. This conversion may be achieved under acidic conditions (such as, but not restricted to, heating with trifluoroacetic acid or aqueous hydrochloric acid in a solvent such as isopropanol or n-butanol) or basic conditions (such as, but not restricted to, treatment with sodium hexamethyldisilazide in tetrahydrofuran at low temperature). The compound of formula (XXI) may then be converted to a compound of formula (XXII) by treatment with a dialkyl acetal of dimethylformamide or an equivalent chemical entity, followed by reaction with hydrazine in aqueous ethanol. The compound of formula (XXII) may then be reacted with R 4 X (wherein X represents a leaving group such as, but not restricted to, halide, trifluorosulfonate, mesylate or tosylate) to afford the compound of formula (IX). This reaction may be performed in the presence of base, such as potassium t-butoxide or potassium carbonate, in an inert solvent, such as tetrahydrofuran or dimethylformamide, under an inert atmosphere. Depending on the nature of the alkylating agent and the reaction conditions, the compound of formula (IX) may be isolated as a pure regioisomer or a mixture of the two possible regioisomers (where the R 4 group is on either N atom of the pyrazole ring). In the case where a mixture of regioisomers is obtained, these isomers may be separated by physical methods (such as crystallization or chromatographic methods) at this stage or any other later stage in the synthetic scheme. The compound of formula (IX) may be converted to the compound of formula (I) according to the procedures outlined in Scheme 1.
[0034] Alternatively, treating the compound of formula (XXI) with the hydrazine R 4 NHNH 2 (which is commercially available or may be synthesized using techniques conventional in the art) yields a compound of formula (XXIII), which may then be reacted with the dialkyl acetal of dimethylformamide or equivalent chemical entity to generate the compound of formula (IX), where the R 4 group is attached to the specified N atom of the pyrazole ring. The compound of formula (IX) may then be converted to the compound of formula (I), where the R 4 group is attached to the specified N atom of the pyrazole ring, according to the procedure outlined on Scheme 1.
[0000]
[0035] Alternatively, the compound of formula (IX) may be synthesized as shown in Scheme 5. The compound of formula (XXIV), which may be commercially available or prepared according to procedures familiar to those skilled in the art, may be reacted with a solution of DMA in DMF, followed by treatment with hydrazine, to afford the compound of formula (XXV) The compound of formula (XXV) may be reacted with the alkylating agent R 4 X (wherein X represents a leaving group such as, but not restricted to, halide, trifluorosulfonate, mesylate or tosylate) to afford the compound of formula (XXVI). This reaction may be performed in the presence of base, such as sodium hydride, cesium carbonate, potassium t-butoxide or potassium carbonate, in an inert solvent, such as tetrahydrofuran or dimethylformamide, under an inert atmosphere. The compound of formula (XXVI) may then be reacted with a brominating agent, such as NBS in DMF or bromine in chloroform, to yield the compound of formula (XXVII). The compound of formula (XXV) may also be first brominated, using a brominating agent such as NBS in DMF, and then alkylated with the alkylating agent R 4 X in the presence of a base in an inert solvent, to generate the compound of formula (XXVII). The compound of formula (XXVII) may then be submitted to standard borylation conditions (such as diborondipinacolate in the presence of a catalyst, such as palladium (II) dichloride bis(triphenylphosphine), and a base, such as potassium acetate, in an inert solvent, such as dioxane), to yield the compound of formula (XXVIII). The compound of formula (XXVIII) may then be reacted with 2,4-dichloropyrimidine, in a solvent such as methanol or ethanol, in the presence of a base such as sodium carbonate and a catalyst such as palladium (II) dichloride bis(triphenylphosphine), to afford the compound of formula (XXIX). The compound of formula (XXIX) may finally be reacted with the aniline of formula (VIII) in the presence of acid to afford the compound of formula (IX).
[0000]
[0036] Alternatively, the compound of compound (IX) may be synthesized as shown in Scheme 6. The commercially available 4-thiouracyl (XXX) may be alkylated to afford the compound of formula (XXXI). This compound may be treated with phosphorus oxybromide to afford the bromide of formula (XXXII), which may be oxidized, using a reagent such as mCPBA, to the corresponding sulfone of formula (XXXIII). The sulfone (XXXIII) may be reacted with the aniline of formula (VIII), in the presence of a strong base such as sodium hexamethyldisilazide, to afford the compound of formula (XXXIV). A Suzuki coupling between compound (XXXIV) and compound (XXVIII), using palladium dichloride bis(triphenylphosphine) as the catalyst, maybe be used to generate the compound of formula (IX).
[0000]
[0037] Alternatively, the compound of formula (IX) may also be generated according the reactions displayed in Scheme 7. The compound of formula (XXXIII) may be reacted with the aniline of formula (VIII) or its Boc protected version of formula (XXXV), in the presence of a base such as an alkaline hexamethyldisilazide, in an inert solvent such as THF, to afford the compound of formula (XXXVI). The compound of formula (XXXVI) may be converted to the boronate of formula (XXXVII), which may be coupled to the bromide of formula (XXVII) to afford the compound of formula (XXXVIII) when R′″ is Boc or the compound of formula (IX) when R′″ is H. The compound of formula (XXXVIII), where R′″ is Boc, may be converted to the compound of formula (IX) by acidic deprotection using, for example, hydrochloric or trifluoroacetic acid. The compound of formula (IX) may then be used to generate compound of formula (I) according to the transformations described in Scheme 1.
[0000]
[0038] Alternatively, the compound of formula (IX) may also be generated according the reactions displayed in Scheme 8. The compound of formula (XXVI) may be converted to the iodide of formula (XXXIX) by reaction with N-iodo-succinimide, for example. The compound of formula (XXXIX) may also be prepared by conversion of compound (XXV) to the iodide of formula (XXXX) using N-iodo-succinimide, followed by alkylation with R 4 X. The compound of formula (XXXIX) may then be converted to the acetyl compound of formula (XXXXI) by treatment with trimethylsilylacetylene, copper (I) iodide, triethylamine and bis(triphenylphosphine)palladium (II) dichloride in toluene, followed by acidic hydrolysis, using conditions such as trifluoroacetic acid in a mixture of water and methylene chloride. The compound of formula (XXXXI) may then be converted to the compound of formula (XXXXII) by treatment with dimethylformamide di-t-butyl acetal. In parallel, the aniline of formula (VIII) may be converted to the guanidine of formula (XXXXIII) by initial treatment with N,N′-bis-t-butoxycarbonyl-1H-pyrazole-1-carboxamidine, followed by acidic treatment with trifluoroacetic acid or hydrochloric acid. This transformation may also be performed in a single step using 1H-pyrazole-1-carboxamidine. The compound of formula (XXXXIII) may then be reacted with the compound of formula (XXXXII) at elevated temperature (such as 125° C.) in an inert solvent, such as dimethylformamide, to afford the compound of formula (IX).
[0000]
Methods of Use
[0039] The compounds of the invention can be used to treat diseases of cellular proliferation, autoimmunity or inflammation. Disease states which can be treated by the compounds of the invention include, but are not limited to, cancer, autoimmune disease, fungal disorders, arthritis, graft rejection, inflammatory bowel disease, proliferation induced after medical procedures, including, but not limited to, surgery, angioplasty and the like (see below for further discussion of selected disease states). It is appreciated that in some cases the cells may not be in a hyper- or hypoproliferation state (abnormal state) and still require treatment. Thus, in certain embodiments, the invention includes application to cells or individuals afflicted or impending affliction with any one of these disorders or states.
Proliferative Disease/Cancer
[0040] The present invention is directed to a class of novel kinase inhibitors, particularly inhibitors of Aurora (A, B and/or C) kinase. The present invention makes use of the finding that Aurora kinase serves multiple essential functions required for the completion of mitosis and that inhibition of the kinase activity of Aurora frequently results in cell cycle arrest and/or abnormal cell division, both of which can trigger cell death. Thus, by inhibiting Aurora kinase, cellular proliferation is blocked.
[0041] The compounds of the invention find use in a variety of applications. As will be appreciated by those skilled in the art, mitosis may be altered in a variety of ways; that is, mitosis can be affected either by increasing or decreasing the activity of a component in the mitotic pathway. Stated differently, mitosis may be disrupted by disturbing equilibrium, either by inhibiting or activating certain components. Similar approaches may be used to alter meiosis.
[0042] The compounds of the invention provided herein are particularly deemed useful for the treatment of cancer including solid tumors, such as skin, breast, brain, cervical carcinomas, testicular carcinomas and others. More particularly, cancers that may be treated using the compounds of the invention include, but are not limited to: Cardiac: sarcoma (angiosarcoma, fibrosarcoma, rhabdomyosarcoma, liposarcoma), myxoma, rhabdomyoma, fibroma, lipoma and teratoma; Lung: bronchogenic carcinoma (squamous cell, undifferentiated small cell, undifferentiated large cell, adenocarcinoma), alveolar (bronchiolar) carcinoma, bronchial adenoma, sarcoma, lymphoma, chondromatous hamartoma, mesothelioma; Gastrointestinal: esophagus (squamous cell carcinoma, adenocarcinoma, leiomyosarcoma, lymphoma), stomach (carcinoma, lymphoma, leiomyosarcoma), pancreas (ductal adenocarcinoma, insulinoma, glucagonoma, gastrinoma, carcinoid tumors, vipoma), small bowel (adenocarcinoma, lymphoma, carcinoid tumors, Karposi's sarcoma, leiomyoma, hemangioma, lipoma, neurofibroma, fibroma), large bowel (adenocarcinoma, tubular adenoma, villous adenoma, hamartoma, leiomyoma); Genitourinary tract: kidney (adenocarcinoma, Wilm's tumor (nephroblastoma), lymphoma, leukemia), bladder and urethra (squamous cell carcinoma, transitional cell carcinoma, adenocarcinoma), prostate (adenocarcinoma, sarcoma), testis (seminoma, teratoma, embryonal carcinoma, teratocarcinoma, choriocarcinoma, sarcoma, interstitial cell carcinoma, fibroma, fibroadenoma, adenomatoid tumors, lipoma); Liver: hepatoma (hepatocellular carcinoma), cholangiocarcinoma, hepatoblastoma, angiosarcoma, hepatocellular adenoma, hemangioma; Bone: osteogenic sarcoma (osteosarcoma), fibrosarcoma, malignant fibrous histiocytoma, chondrosarcoma, Ewing's sarcoma, malignant lymphoma (reticulum cell sarcoma), multiple myeloma, malignant giant cell tumor chordoma, osteochronfroma (osteocartilaginous exostoses), benign chondroma, chondroblastoma, chondromyxofibroma, osteoid osteoma and giant cell tumors; Nervous system: skull (osteoma, hemangioma, granuloma, xanthoma, osteitis deformans), meninges (meningioma, meningiosarcoma, gliomatosis), brain (astrocytoma, medulloblastoma, glioma, ependymoma, germinoma (pinealoma), glioblastoma multiform, oligodendroglioma, schwannoma, retinoblastoma, congenital tumors), spinal cord (neurofibroma, meningioma, glioma, sarcoma); Gynecological: uterus (endometrial carcinoma), cervix (cervical carcinoma, pre-tumor cervical dysplasia), ovaries (ovarian carcinoma, serous cystadenocarcinoma, mucinous cystadenocarcinoma, unclassified carcinoma), granulosa-thecal cell tumors, Sertoli-Leydig cell tumors, dysgerminoma, malignant teratoma, vulva (squamous cell carcinoma, intraepithelial carcinoma, adenocarcinoma, fibrosarcoma, melanoma), vagina (clear cell carcinoma, squamous cell carcinoma, botryoid sarcoma (embryonal rhabdomyosarcoma)), fallopian tubes (carcinoma); Hematologic: blood (myeloid leukemia (acute and chronic), acute lymphoblastic leukemia, chronic lymphocytic leukemia, myeloproliferative diseases, multiple myeloma, myelodysplastic syndrome), Hodgkin's disease, non-Hodgkin's lymphoma (malignant lymphoma); Skin: malignant melanoma, basal cell carcinoma, squamous cell carcinoma, Karposi's sarcoma, moles dysplastic nevi, lipoma, angioma, dermatofibroma, keloids, psoriasis; and Adrenal glands: neuroblastoma. Thus, the term “cancerous cell” as provided herein, includes a cell afflicted by any one of the above identified conditions.
[0043] Accordingly, the compounds of the invention are administered to cells. By “administered” herein is meant administration of a therapeutically effective dose of a compound of the invention to a cell either in cell culture or in a patient. By “therapeutically effective dose” herein is meant a dose that produces the effects for which it is administered. The exact dose will depend on the purpose of the treatment, and will be ascertainable by one skilled in the art using known techniques. As is known in the art, adjustments for systemic versus localized delivery, age, body weight, general health, sex, diet, time of administration, drug interaction and the severity of the condition may be necessary, and will be ascertainable with routine experimentation by those skilled in the art. By “cells” herein is meant any cell in which mitosis or meiosis can be altered. A “patient” for the purposes of the present invention includes both humans and other animals, particularly mammals, and other organisms. Thus, the methods are applicable to both human therapy and veterinary applications. In certain embodiments the patient is a mammal, especially a human.
[0044] The compounds of the invention may be administered in a physiologically acceptable carrier to a patient, as described herein. Depending upon the manner of introduction, the compounds may be formulated in a variety of ways as discussed below. The concentration of the compound in the formulation may vary from about 0.1-99.9 wt. %.
[0045] When used to treat proliferative diseases, the compounds of the present invention can be administered alone or in combination with other treatments, i.e., radiation, or other therapeutic agents, such as the taxane class of agents that appear to act on microtubule formation or the camptothecin class of topoisomerase I inhibitors. When so used, other therapeutic agents may be administered before, concurrently with (whether in separate dosage forms or in a combined dosage form) or after administration of the compound of the invention.
Compositions
[0046] The compounds of the invention will normally, but not necessarily, be formulated into pharmaceutical compositions prior to administration to a patient. Accordingly, in another aspect the invention is directed to pharmaceutical compositions comprising a compound of the invention and one or more pharmaceutically acceptable excipient. The pharmaceutical compositions of the invention may be prepared and packaged in bulk form wherein a safe and effective amount of a compound of the invention can be extracted and then given to the patient, such as with powders or syrups. Alternatively, the pharmaceutical compositions of the invention may be prepared and packaged in unit dosage form wherein each physically discrete unit contains a safe and effective amount of a compound of the invention. When prepared in unit dosage form, the pharmaceutical compositions of the invention typically contain from about 0.1 to 99.9 wt. %, depending on the nature of the formulation.
[0047] As used herein, “pharmaceutically acceptable excipient” means a pharmaceutically acceptable material, composition or vehicle involved in giving form or consistency to the pharmaceutical composition. Each excipient is advantageously compatible with the other ingredients of the pharmaceutical composition when comingled, such that interactions which would substantially reduce the efficacy of the compound of the invention when administered to a patient and would result in pharmaceutically unacceptable compositions are avoided. In addition, each excipient is sufficiently high in purity to render it pharmaceutically acceptable.
[0048] The compound of the invention and the pharmaceutically acceptable excipient or excipients will typically be formulated into a dosage form adapted for administration to the patient by the desired route of administration. For example, dosage forms include those adapted for (1) oral administration, such as tablets, capsules, caplets, pills, troches, powders, syrups, elixers, suspensions, solutions, emulsions, sachets, and cachets; (2) parenteral administration, such as sterile solutions, suspensions, and powders for reconstitution; (3) transdermal administration, such as transdermal patches; (4) rectal administration, such as suppositories; (5) inhalation, such as aerosols and solutions; and (6) topical administration, such as creams, ointments, lotions, solutions, pastes, sprays, foams, and gels.
[0049] Suitable pharmaceutically acceptable excipients will vary depending upon the particular dosage form chosen. In addition, suitable pharmaceutically acceptable excipients may be chosen for a particular function that they may serve in the composition. For example, certain pharmaceutically acceptable excipients may be chosen for their ability to facilitate the production of uniform dosage forms. Certain pharmaceutically acceptable excipients may be chosen for their ability to facilitate the production of stable dosage forms. Certain pharmaceutically acceptable excipients may be chosen for their ability to facilitate the carrying or transporting the compound or compounds of the invention once administered to the patient from one organ, or portion of the body, to another organ, or portion of the body. Certain pharmaceutically acceptable excipients may be chosen for their ability to enhance patient compliance.
[0050] Suitable pharmaceutically acceptable excipients include the following types of excipients: Diluents, fillers, binders, disintegrants, lubricants, glidants, granulating agents, coating agents, wetting agents, solvents, co-solvents, suspending agents, emulsifiers, sweetners, flavoring agents, flavor masking agents, coloring agents, anticaking agents, hemectants, chelating agents, plasticizers, viscosity increasing agents, antioxidants, preservatives, stabilizers, surfactants, and buffering agents. The skilled artisan will appreciate that certain pharmaceutically acceptable excipients may serve more than one function and may serve alternative functions depending on how much of the excipient is present in the formulation and what other ingredients are present in the formulation.
[0051] Skilled artisans possess the knowledge and skill in the art to enable them to select suitable pharmaceutically acceptable excipients in appropriate amounts for use in the invention. In addition, there are a number of resources that are available to the skilled artisan which describe pharmaceutically acceptable excipients and may be useful in selecting suitable pharmaceutically acceptable excipients. Examples include Remington's Pharmaceutical Sciences (Mack Publishing Company), Remington: The Science and Practice of Pharmacy , (Lippincott Williams & Wilkins), The Handbook of Pharmaceutical Additives (Gower Publishing Limited), and The Handbook of Pharmaceutical Excipients (the American Pharmaceutical Association and the Pharmaceutical Press).
[0052] The pharmaceutical compositions of the invention are prepared using techniques and methods known to those skilled in the art. Some of the methods commonly used in the art are described in Remington's Pharmaceutical Sciences (Mack Publishing Company).
[0053] Oral solid dosage forms such as tablets will typically comprise one or more pharmaceutically acceptable excipients, which may for example help impart satisfactory processing and compression characteristics, or provide additional desirable physical characteristics to the tablet. Such pharmaceutically acceptable excipients may be selected from diluents, binders, glidants, lubricants, disintegrants, colorants, flavorants, sweetening agents, polymers, waxes or other solubility-modulating materials.
[0054] Dosage forms for parenteral administration will generally comprise fluids, particularly intravenous fluids, i.e., sterile solutions of simple chemicals such as sugars, amino acids or electrolytes, which can be easily carried by the circulatory system and assimilated. Such fluids are typically prepared with water for injection USP. Fluids used commonly for intravenous (IV) use are disclosed in Remington, The Science and Practice of Pharmacy [full citation previously provided], and include:
alcohol, e.g., 5% alcohol (e.g., in dextrose and water (“D/W”) or D/W in normal is saline solution (“NSS”), including in 5% dextrose and water (“D5/W”), or D5/W in NSS); synthetic amino acid such as Aminosyn, FreAmine, Travasol, e.g., 3.5 or 7; 8.5; 3.5, 5.5 or 8.5% respectively; ammonium chloride e.g., 2.14%; dextran 40, in NSS e.g., 10% or in D5/W e.g., 10%; dextran 70, in NSS e.g., 6% or in D5/W e.g., 6%; dextrose (glucose, D5/W) e.g., 2.5-50%; dextrose and sodium chloride e.g., 5-20% dextrose and 0.22-0.9% NaCl; lactated Ringer's (Hartmann's) e.g., NaCl 0.6%, KCl 0.03%, CaCl 2 0.02%; lactate 0.3%; mannitol e.g., 5%, optionally in combination with dextrose e.g., 10% or NaCl e.g., 15 or 20%; multiple electrolyte solutions with varying combinations of electrolytes, dextrose, fructose, invert sugar Ringer's e.g., NaCl 0.86%, KCl 0.03%, CaCl 2 0.033%; sodium bicarbonate e.g., 5%; sodium chloride e.g., 0.45, 0.9, 3, or 5%; sodium lactate e.g., ⅙ M; and sterile water for injection
[0070] The pH of such IV fluids may vary, and will typically be from 3.5 to 8 as known in the art.
[0071] It will be appreciated that when the compounds of the present invention are administered in combination with other therapeutic agents normally administered by the inhaled, intravenous, oral or intranasal route, that the resultant pharmaceutical composition may be administered by the same routes.
[0072] Compounds of the invention may conveniently be administered in amounts of, for example, 0.001 to 500 mg/kg body weight. The precise dose will of course depend on the age and condition of the patient and the particular route of administration chosen.
[0073] Compounds of the invention were tested for in vitro activity in accordance with the following assays. The following compounds have an IC 50 of less than 10 μM for Aurora A or Aurora B or both as determined by the following assays described.
Aurora A Enzyme Activity Assay
[0074] Compounds of the present invention were tested for Aurora A protein kinase inhibitory activity in substrate phosphorylation assays. This assay examines the ability of small molecule organic compounds to inhibit the serine phosphorylation of a peptide substrate, and was run in the LEADseeker (Amersham Bioscience, Piscataway, N.J.) scintillation proximity assay (SPA) format.
[0075] The substrate phosphorylation assays use recombinant human full-length Aurora A kinase expressed in baculovirus/Sf9 system. A N-terminal His-Thr-affinity tag was fused to the amino terminus of amino acids 2 through 403 of Aurora A. 5 nM okadaic acid was added during the last 4 hours of expression (experimentally determined to enhance Aurora A's enzymatic activity). The enzyme was purified to approximately 70% purity by metal-chelate affinity chromatography.
[0076] The method measures the ability of the isolated enzyme to catalyze the transfer of the gamma-phosphate from ATP onto the serine residue of a biotinylated synthetic peptide (Biotin-aminohexyl-RARRRLSFFFFAKKK-amide). Substrate phosphorylation was detected by the following procedure: Assays were performed in 384-well low volume white polystyrene plates (Greiner Bio-One, Longwood, Fla.). 1 nM Aurora A enzyme was added to the wells containing 0.1 μl of test compound in 100% DMSO and incubated for 30 minutes, followed by the addition of reaction mixture resulting in a final assay volume of 10 μl containing 6 mM magnesium chloride, 1.5 μM ATP, 1 μM peptide substrate, 40 nM microtubule associated protein TPX2 peptide (1-43), 0.03 μCi [gamma-P 33 ] ATP/well, 5 mM DTT, 25 mM KCl, 0.15 mg/ml BSA and 0.01% Tween-20 in 50 mM HEPES, pH 7.2. The reaction was allowed to proceed for 120 minutes at room temperature and was terminated by the addition of 10 μl of a LEADseeker SPA bead solution containing PBS (Dulbecco's PBS without Mg 2+ and Ca 2+ ), 50 mM EDTA, 0.03 mg of Streptavidin coupled polystyrene imaging beads (Amersham Bioscience). The plate was sealed and the beads were allowed to incubate overnight. The plate was read in a Viewlux (Wallac, Turku, Finland) plate reader.
[0077] For dose response curves, data were normalized and expressed as % inhibition using the formula 100*(1−(U−C2)/(C1−C2)) where U is the unknown value, C1 is the average of the high signal (0% inhibition) and C2 is the average of the low signal (100% inhibition) control wells. Curve fitting was performed with the following equation: y=A+((B−A)/(1+(10̂x/10̂C)̂D)), where A is the minimum response, B is the maximum response, C is the log 10(XC50), and D is the slope. The results for each compound were recorded as pIC50 values (−C in the above equation).
Aurora B Enzyme Activity Assay
[0078] Compounds of the present invention were tested for Aurora B protein kinase inhibitory activity in substrate phosphorylation assays. This assay examines the ability of small molecule organic compounds to inhibit the serine phosphorylation of a peptide substrate, and was run in the LEADseeker (Amersham Bioscience) scintillation proximity assay (SPA) format.
[0079] The substrate phosphorylation assays use recombinant human full-length Aurora B kinase expressed in baculovirus/Sf9 system. Following expression the culture is incubated with 50 nM okadaic acid for 1 hour prior to purification. An N-terminal His-affinity tag was fused to the amino terminus of amino acids 1 through 344 of Aurora B. 5 μM Aurora B was activated in 50 mM Tris-HCl pH 7.5, 0.1 mM EGTA, 0.1% 2-mercaptoethanol, 0.1 mM sodium vandate, 10 mM magnesium acetate, 0.1 mM ATP with 0.1 mg/ml GST-INCENP [826-919] at 30° C. for 30 mins. Following activation the enzyme is then dialysed into enzyme storage buffer and stored at −70° C.
[0080] The method measures the ability of the isolated enzyme to catalyze the transfer of the gamma-phosphate from ATP onto the serine residue of a biotinylated synthetic peptide (Biotin-aminohexyl-RARRRLSFFFFAKKK-amide). Substrate phosphorylation was detected by the following procedure: Assays were performed in 384-well low volume white polystyrene plates (Greiner Bio-One, Longwood, Fla.). 5 nM Aurora B enzyme was added to the wells containing 0.1 μl of test compound in 100% DMSO and incubated for 30 minutes followed by the addition of reaction mixture resulting in a final assay volume of 10 μl containing 6 mM magnesium chloride, 3 mM manganese chloride, 1.25 μM ATP, 1.25 μM peptide substrate, 0.025 μCi [gamma-P 33 ] ATP/well, 5 mM DTT, 0.15 mg/ml BSA, 0.01% Tween-20 in 50 mM HEPES pH 7.5, and 0.1 μl of test compound in 100% DMSO. The reaction was allowed to proceed for 120 minutes at room temperature and was terminated by the addition of 10 μl of a LEADseeker SPA bead solution containing PBS (Dulbecco's PBS without Mg 2+ and Ca 2+ ), 50 mM EDTA, 0.03 mg of Streptavidin coupled polystyrene imaging beads (Amersham Bioscience). The plate was sealed and the beads were allowed to incubate overnight. The plate was read in a Viewlux (Wallac, Turku, Finland) plate reader.
[0081] For dose response curves, data were normalized and expressed as % inhibition using the formula 100*(1−(U−C2)/(C1−C2)) where U is the unknown value, C1 is the average of the high signal (0% inhibition) and C2 is the average of the low signal (100% inhibition) control wells. Curve fitting was performed with the following equation: y=A+((B−A)/(1+(10̂X/10̂C)̂D)), where A is the minimum response, B is no the maximum response, C is the log 10(XC50), and D is the slope. The results for each compound were recorded as pIC50 values (−C in the above equation).
Cellular Proliferation Assay:
[0082] The ability of compounds to inhibit the proliferation of human tumor or normal cells was investigated using cell proliferation assays. Briefly, cells are seeded into 96 well plates at an appropriate density for each cell type to ensure logarithmic growth throughout the assay and allowed to adhere overnight. Compounds are dissolved in 100% DMSO at approximately 10 mM and two-fold serially dilutions are made in 100% DMSO spanning twenty concentration points. Compounds are diluted 500-fold into cell culture media and incubated on cells for three days. Cell viability is determined using Promega's CellTiter-Glo reagent as per manufacturer's instructions. Percent growth proliferation is calculated relative to DMSO alone treated cells and IC50 values are determined by a four-parameter fit model using XIfit (IDBS, Inc.).
General Purification and Analytical Methods
[0083] Analytical HPLC was conducted on a Zorbex Eclipse XD8-C18 column (4.6×150 mm, 5 um), using H 2 O with 0.05% TFA (solvent A) and CH 3 CN with 0.05% TFA (solvent B). The elution gradient was 10-90% B over 15 min; flow 1.0 mL/min. Detection: 230 and 254 nm. Retention times (t R ) are reported in minutes.
[0084] Preparative HPLC was conducted on a Phenomenex Gemini 5u C18 110A (100×30.0 mm, 5 μm), using H 2 O with 0.1% formic acid (solvent A) and CH 3 CN with 0.1% formic acid (solvent B). The isocratic elution used was 18-24% B over 8 min, then gradient ramp up to 90% B over 2 min; flow 55 mL/min. Detection: 230 or 254 nm.
[0085] LC-MS analysis was performed on a Perkin Elmer Sciex 100 atmospheric pressure ionization (APCI) mass spectrometer. Retention times in LC-MS are referred to as t R (time in minutes).
[0086] 1 H NMR spectra were recorded using a Bruker DPX 400 MHz spectrometer referenced to tetramethylsilane. Chemical shifts are expressed in parts per million (ppm, δ units). Coupling constants are in units of hertz (Hz). Splitting patterns describe apparent multiplicities and are designated as s (singlet), d (doublet), t (triplet), q (quartet), m (multiplet), br (broad).
[0087] Analogix™ chromatography refers to purification carried out using equipment sold by Analogix Corporation (IntelliFlash 280) and cartridges PuriFlash (RS or SF) pre-packed with PuriSil. Hydrophobic filtration frits were obtained from Whatman. TLC (thin layer chromatography) plates coated with silica gel 60 F254 were obtained from Merck.
[0088] Examples or intermediates purified by preparative HPLC were obtained as the corresponding formate salt, unless specified differently.
EXAMPLES
[0089] The following examples are for illustrative purposes only and are not intended to limit the scope of this invention. As used herein, the symbols and conventions used in these processes, schemes and examples are consistent with those used in the contemporary scientific literature, for example, the Journal of the American Chemical Society or the Journal of Biological Chemistry. Standard single-letter or three-letter abbreviations are generally used to designate amino acid residues, which are assumed to be in the L-configuration unless otherwise noted. All temperatures are in ° C. Unless otherwise noted, all starting materials were obtained from commercial suppliers and used without further purification. Specifically, the following abbreviations may be used in the examples and throughout the specification:
[0000]
g (grams);
mg (milligrams);
L (liters);
mL (milliliters);
μL (microliters);
psi (pounds per square inch);
M (molar);
mM (millimolar);
Hz (Hertz);
MHz (megahertz);
mmol (millimoles);
mol (moles);
min (minutes);
h (hours);
mp (melting point);
TLC (thin layer chromatography);
HPLC (high pressure liquid chromatography);
atm (atmosphere);
t R (retention time);
RP (reverse phase);
MeOH (methanol);
i-PrOH (isopropanol);
TEA (triethylamine);
TFA (trifluoroacetic acid);
THF (tetrahydrofuran);
DMSO (dimethylsulfoxide);
AcOEt (EtOAc);
DCM (CH2Cl2);
DMF (N,N-dimethylformamide);
HOAc (acetic acid);
mCPBA (meta-chloroperbenzoic acid);
BOC (tert-butyloxycarbonyl);
Ac (acetyl);
DMAP (4-dimethylaminopyridine)
ATP (adenosine triphosphate);
BSA (bovine serum albumin)
HBTU (O-Benzotriazole-1-yl-N,N,N′,N′-tetramethyluronium
hexafluorophosphate);
HEPES (4-(2-hydroxyethyl)-1-piperazine ethane sulfonic acid);
DMF (N,N-dimethylformamide);
NaHMDS (sodium hexamethyldisilazide)
DMF-DMA (N,N-dimethylformamide dimethylacetal).
[0090] All references to ether are to diethyl ether; brine refers to a saturated aqueous solution of NaCl. Unless otherwise indicated, all temperatures are expressed in ° C. (degrees Centigrade). All reactions are conducted under an inert atmosphere at room temperature unless otherwise noted.
Intermediate 1
4-Methyl-2-(methylthio)pyrimidine
[0091] A suspension of 2-thio-4-methylpyrimidine (20.0 g) and methyl iodide (7.65 g) in ethanol (615 mL) and 1M NaOH (246 mL) was stirred at room temperature for 16 h. The reaction mixture was concentrated under reduced pressure to 200 mL, and then the reaction mixture was extracted with ethyl acetate (300 mL×2). The organic layers were combined and washed with water, brine, and dried with anhydrous Na 2 SO 4 . The mixture was filtered and concentrated to afford the title compound as clear brown oil.
Intermediate 2
Ethyl 4-[(phenylcarbonyl)amino]benzoate
[0092] A suspension of ethyl 4-aminobenzate (10.0 g) in methylene chloride (250 mL) and triethylamine (17.5 mL) was treated with benzoyl chloride at 0° C., allowed to warm to room temperature and stirred for 16 h. The reaction mixture was diluted with water (300 mL) and extracted with methylene chloride (200 mL×2). The organic layers were washed with water, brine, and dried with anhydrous Na 2 SO 4 . The mixture was filtered and concentrated. The residue was dissolved in hot diethyl ether, then cooled to 0° C. The title compound was isolated after filtration of the diethyl ether solution. 1 H NMR (400 MHz, CDCl 3 ) δ ppm 8.09 (d, J=8.8 Hz, 2H), 7.98 (s, 1H) 7.94-7.89 (m, 2H), 7.77 (d, J=8.8 Hz, 2H), 7.64-7.60 (m, 1H), 7.57-7.52 (m, 2H), 4.40 (q, J=7.1 Hz, 2H), 1.42 (t, J=7.2 Hz, 3H); ESI MS (m/z) 270 [M+H] + .
Intermediate 3
N-(4-{2-[2-(Methylthio)-4-pyrimidinyl]acetyl}phenyl)benzamide
[0093] A suspension of 4-methyl-2-(methylthio)pyrimidine (3.5 g) and ethyl 4-[(phenylcarbonyl)amino]benzoate (6.72 g) in THF (160 mL) was treated with 1M lithium bis(trimethylsiyl)amide solution in THF (80 mL) at −78° C. The reaction mixture was warmed to 0° C. over the period of 3 h. The reaction mixture was then poured into a 1:1 mixture of 1M hydrochloric acid/ice (80 mL each) and stirred for 2 h. The reaction mixture was filtered to afford the title compound as a yellow solid. ESI MS (m/z) 364 [M+H] + ; LC-MS, t R (enol)=2.10 min, t R (ketone)=2.52 min.
Intermediate 4
N-(4-{4-[2-(Methylthio)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenylbenzamide
[0094] A suspension of N-(4-{2-[2-(methylthio)-4-pyrimidinyl]acetyl}phenyl)benzamide (5.0 g) in N,N-dimethylformamide dimethyl acetal (36 mL) was heated to 100° C. for 3 h. The solvent was then removed under reduced pressure. The crude residue was dissolved in ethanol (40 mL), and treated with 35 wt % hydrazine solution in water (9.96 mL) at 0° C. for 3 h. The solvent was removed under reduced pressure. The residue was washed with hot methylene chloride. The title compound was isolated after filtration of the methylene chloride solution. 1 H NMR (400 MHz, CDCl 3 ) δ ppm 10.55 (m, 1H), 8.33 (d, J=5.3 Hz, 1H), 8.24 (s, 2H), 8.01 (s, 1H), 7.91-7.96 (m, 2H), 7.78 (d, J=8.6 Hz, 2H), 7.63-7.52 (m, 4H), 6.88 (d, J=5.3 Hz, 1H), 2.50 (s, 3H); ESI MS (m/z) 388 [M+H] + ; analytical HPLC t R =5.67 min.
Intermediate 5
N-(4-{4-[2-(Methylsulfonyl)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenylbenzamide
[0095] A suspension of N-(4-{4-[2-(methylthio)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)benzamide (489 mg) in methylene chloride (12 mL) was treated with 3-chloroperoxy benzoic acid (849 mg) at 0° C. and then warmed to room temperature. After 3 h, the reaction was diluted with water (40 mL) and extracted with methylene chloride (4×20 mL). The methylene chloride layers were concentrated. The title compound was isolated by purification of this residue by pad of Silica gel using ethyl acetate:hexanes (1:3) as eluent. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 13.60 (s, 1H), 10.43-10.32 (m, 1H), 8.85 (d, J=5.3 Hz, 2H), 8.67 (d, J=1.0 Hz, 1H), 8.31 (d, J=1.5 Hz, 1H), 7.76-7.69 (m, 3H), 7.69-7.63 (m, 2H), 7.55 (d, J=8.8 Hz, 2H), 7.50 (d, J=8.6 Hz, 1H), 3.18-3.15 (m, 3H); ESI MS (m/z) 420 [M+H] + .
Example 1
N-(4-{4-[2-({3-[2-(4-Morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)benzamide
[0096] A suspension of N-(4-{4-[2-(methylsulfonyl)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)benzamide (51 mg) and 3-[2-(4-morpholinyl)ethyl]aniline (30 mg) in THF (3 mL) was treated with 1M sodium bis(trimethylsilyl)amide solution in THF at −78° C. The reaction mixture was warmed to 0° C. for 1 h. The reaction mixture was diluted with saturated aqueous sodium bicarbonate (5 mL), extracted with ethyl acetate (3×8 mL), and dried with Na 2 SO 4 . The combined organic layers were filtered and concentrated. The residue was dissolved with hot methylene chloride, diluted with hexanes, and cooled to 0° C. The title compound was isolated after filtration of the methylene chloride:hexanes solution. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 13.41-13.34 (m, 1H), 10.44-10.35 (m, 1H), 9.42 (d, J=5.3 Hz, 1H), 8.30 (d, J=5.6 Hz, 1H), 8.07-7.84 (m, 4H), 7.63-7.54 (m, 6H), 7.46 (d, J=8.1 Hz, 1H), 7.09-7.06 (m, 1H), 6.75 (d, J=7.3 Hz, 1H), 6.66 (d, J=5.0 Hz, 1H), 3.59-3.56 (m, 4H), 2.69-2.63 (m, 2H), 2.54-2.50 (m, 2H), 2.44-2.39 (m, 4H); ESI MS (m/z) 546 [M+H] + ; analytical HPLC t R =4.32 min.
Intermediate 6
Mixture of N-(4-{1-methyl-4-[2-(methylsulfonyl)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)benzamide & N-(4-{1-Methyl-4-[2-(methylsulfonyl)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)benzamide
[0097] A suspension of N-(4-{4-[2-(methylsulfonyl)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)benzamide (419 mg) in DMF (10 mL) was treated with potassium tert-butoxide (136 mg) and methyl iodide (71 μL) at 0° C. and then warmed to room temperature. After 2 h, the reaction mixture was diluted with saturated aqueous sodium bicarbonate (5 mL) and extracted with ethyl acetate (3×8 mL). The ethyl acetate layers were concentrated. The residue was purified by flash chromatography to give the title compounds as a white solid. ESI MS (m/z) 434 [M+H] + ; HPLC t R =5.29, 5.39 min.
Examples 2 and 3
[0098] A suspension of N-(4-{1-methyl-4-[2-(methylsulfonyl)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)benzamide and N-(4-{1-methyl-4-[2-(methylsulfonyl)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)benzamide (140 mg, 1:1 mixture) and 3-[2-(4-morpholinyl)ethyl]aniline (80 mg) in THF (8 mL) was treated with 1M sodium bis(trimethylsilyl)amide solution in THF (1.61 mL) at −78° C. The reaction mixture was warmed to 0° C. for 1 h. The reaction mixture was diluted with saturated aqueous sodium bicarbonate (5 mL), extracted with ethyl acetate (3×8 mL), and dried with Na 2 SO 4 . The mixture was filtered and concentrated. The crude product was purified via semi-preparative HPLC to afford separated title compounds as white solids.
Example 2
N-(4-{1-Methyl-4-[2-({3-[2-(4-morpholin-1)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)benzamide
[0099] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.51 (s, 1H), 9.41 (s, 1H), 8.22 (d, J=5.3 Hz, 1H), 8.11 (s, 1H), 8.03-7.96 (m, 4H), 7.65-7.55 (m, 3H), 7.49-7.44 (m, 3H), 7.13 (t, J=7.8 Hz, 1H), 6.78 (d, J=7.6 Hz, 1H), 6.31 (d, J=5.1 Hz, 2H), 3.71 (s, 3H), 3.61-3.53 (m, 4H), 2.73-2.64 (m, 2H), 2.54-2.50 (m, 2H), 2.45-2.42 (s, 4H); ESI MS (m/z) 560 [M+H] + ; analytical HPLC t R =4.71 min.
Example 3
N-(4-{1-Methyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)benzamide
[0100] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.35 (s, 1H), 9.46-9.40 (m, 1H), 8.32 (d, J=5.1 Hz, 1H), 8.26 (s, 1H), 8.15 (s, 1H), 7.96 (d, J=8.6 Hz, 2H), 7.84 (d, J=8.6 Hz, 2H), 7.61-7.47 (m, 5H), 7.09 (t, J=7.7 Hz, 1H), 6.76 (d, J=7.6 Hz, 1H), 6.61 (d, J=5.1 Hz, 1H), 3.96 (s, 3H), 3.59-3.55 (m, 4H), 2.67-2.63 (m, 2H), 2.54-2.50 (m, 2H), 2.43-2.33 (m, 4H); ESI MS (m/z) 560 [M+H] + ; analytical HPLC t R =4.56 min.
Example 4
N-[4-(4-{2-[(3-Fluorophenyl)amino]-4-pyrimidinyl}-1H-pyrazol-3-yl)phenyl]benzamide
[0101] This compound was prepared following a procedure analogous to that outlined for Example 1. 1 H NMR (400 MHz, CD 3 OD) δ ppm 8.29 (d, J=5.3 Hz, 1H), 8.29-8.15 (s, 1H), 8.96-8.93 (m, 2H), 7.85 (s, 2H), 7.64-7.53 (m, 6H), 7.30-7.28 (m, 1H), 7.20-7.16 (m, 1H), 6.81-6.79 (m, 1H), 6.67-6.62 (m, 1H); ESI MS (m/z) 451 [M+H] + ; analytical HPLC t R =5.62 min.
Example 5
N-{4-[4-(2-{[3-(4-Methyl-1-piperazinyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}benzamide
[0102] This compound was prepared following a procedure analogous to that outlined for Example 1. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 13.40-13.38 (m, 1H), 10.45-10.36 (m, 1H), 9.31 (s, 1H), 8.29 (d, J=5.0 Hz, 1H), 8.06-7.92 (m, 4H), 7.62-7.51 (m, 5H), 7.42 (s, 1H), 7.15-7.13 (m, 1H), 7.01 (t, J=8.1 Hz, 1H), 6.62 (d, J=5.3 Hz, 1H), 6.50 (dd, J=8.1, 1.8 Hz, 1H), 3.10-3.08 (m, 4H), 2.49-2.41 (m, 4H), 2.22 (s, 3H); ESI MS (m/z) 531 [M+H] + ; analytical HPLC t R =4.31 min.
Example 6
N-(4-{4-[2-({3-[(N,N-Dimethylglycyl)amino]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)benzamide
[0103] This compound was prepared following a procedure analogous to that outlined for Example 1. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 13.37 (d, J=14.1 Hz, 1H), 10.40 (d, J=32.6 Hz, 1H), 9.56 (s, 1H), 9.49 (s, 1H), 8.47-8.09 (m, 1H), 8.30 (d, J=5.3 Hz, 1H), 8.19-8.14 (m, 1H), 7.97 (d, J=7.3 Hz, 2H), 7.95-7.83 (m, 2H), 7.62-7.50 (m, 5H), 7.35-7.30 (m, 1H), 7.20-7.08 (m, 2H), 6.64-6.62 (m, 1H), 3.07 (s, 2H), 2.29 (s, 6H); ESI MS (m/z) 533 [M+H] + ; analytical HPLC t R =4.26 min.
Example 7
N-{4-[4-(2-{[3-(4-Morpholinylmethyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}benzamide
[0104] This compound was prepared following a procedure analogous to that outlined for Example 1. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 13.37 (d, J=21.5 Hz, 1H), 10.40 (d, J=38.9 Hz, 1H), 9.44-9.51 (m, 1H), 8.32-8.19 (m, 2H), 8.00-7.90 (m, 5H), 7.72-7.48 (m, 5H), 7.13-7.11 (m, 1H), 6.83 (d, J=7.6 Hz, 1H), 6.67-6.64 (m, 1H) 3.60-3.56 (m, 4H), 3.35-3.43 (m, 2H) 2.37-2.34 (s, 4H); ESI MS (m/z) 532 [M+H] + ; analytical HPLC t R =4.35 min.
Example 8
N-{4-[4-(2-{[3-(4-Methyl-1-piperazinyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}cyclopropanecarboxamide
[0105] This compound was prepared following a procedure analogous to that outlined for Example 1. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 13.37-13.35 (m, 1H), 10.41-10.29 (m, 1H), 9.29 (s, 1H), 8.29-8.25 (m, 1.5H), 8.05-8.03 (m, 0.5H), 7.74-7.62 (m, 2H), 7.47-7.38 (m, 3H), 7.14-7.11 (m, 1H), 6.99 (t, J=8.1 Hz, 1H), 6.58 (d, J=5.31 Hz, 1H), 6.50 (dd, J=8.2, 1.9 Hz, 1H), 3.10-3.08 (m, 4H), 2.47-2.40 (m, 4H), 2.22 (s, 3H), 1.85-1.76 (m, 1H), 0.82 (d, J=3.5 Hz, 4H); ESI MS (m/z) 495 [M+H] + ; analytical HPLC t R =3.82 min.
Example 9
N-(4-{4-[2-({3-[2-(4-Morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0106] This compound was prepared following a procedure analogous to the one outlined for Example 1. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 13.34 (s, 1H), 10.40-10.35 (m, 1H), 9.40 (s, 1H), 8.31-8.27 (m, 1.5H), 8.07-8.05 (m, 0.5H), 7.70-7.58 (m, 2H), 7.49-7.42 (m, 3H), 7.06 (t, J=7.8 Hz, 1H), 6.76 (d, J=7.8 Hz, 1H), 6.62 (d, J=5.3 Hz, 1H), 3.61-3.54 (m, 4H), 2.67-2.63 (m, 2H), 2.54-2.50 (m, 2H), 2.42-2.39 (m, 4H), 1.83-1.78 (m, 1H), 0.84-0.79 (m, 4H); ESI MS (m/z) 510 [M+H] + ; analytical HPLC t R =3.87 min.
Examples 10 & 11
[0107] These compounds were prepared following a procedure analogous to that outlined for Examples 2 and 3.
Example 10
N-(4-{1-Methyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-yl}phenyl)cyclopropanecarboxamide
[0108] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.46 (s, 1H), 9.40 (s, 1H), 8.20 (d, J=5.3 Hz, 1H), 8.09 (s, 1H), 7.79 (d, J=8.6 Hz, 2H), 7.62 (s, 1H), 7.44-7.39 (m, 3H), 7.11 (t, J=7.8 Hz, 1H), 6.78 (d, J=7.6 Hz, 1H), 6.27 (d, J=5.3 Hz, 1H), 3.68 (s, 3H), 3.62-3.52 (m, 4H), 2.73-2.65 (m, 2H), 2.54-2.50 (m, 2H), 2.44-2.42 (m, 4H), 1.79-1.86 (m, 1H), 0.85-0.83 (m, 4H); ESI MS (m/z) 524 [M+H] + ; analytical HPLC t R =4.24 min.
Example 11
N-(4-{1-Methyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0109] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.28 (s, 1H), 9.41 (s, 1H), 8.30 (d, J=5.1 Hz, 1H), 8.17 (s, 1H), 7.63 (d, J=8.6 Hz, 2H), 7.53 (s, 1H), 7.51-7.44 (s, 1H), 7.46-7.42 (m, 2H), 7.07 (t, J=7.8 Hz, 1H), 6.76 (d, J=7.6 Hz, 1H), 6.58 (d, J=5.1 Hz, 1H), 3.94 (s, 3H), 3.61-3.52 (m, 4H), 2.68-2.60 (m, 2H), 2.54-2.50 (m, 2H), 2.45-2.40 (m, 4H), 1.76-1.83 (m, 1H), 0.77-0.84 (m, 4H); ESI MS (m/z) 524 [M+H] + ; analytical HPLC t R =4.19 min.
Examples 12 & 13
[0110] These compounds were prepared following a procedure analogous to that outlined for Examples 2 and 3.
Example 12
N-{4-[1-Methyl-4-(2-{[3-(4-methylpiperazin-1-yl)phenyl]amino}pyrimidin-4-yl)-1H-pyrazol-5-yl]phenyl}benzamide
[0111] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.51 (s, 1H), 9.29 (s, 1H), 8.20 (d, J=5.3 Hz, 1H), 8.10 (s, 1H), 8.03-7.96 (m, 4H), 7.65-7.55 (m, 3H), 7.51-7.42 (m, 3H), 7.14-7.03 (m, 2H), 6.52 (dd, J=8.1, 1.5 Hz, 1H), 6.28 (d, J=5.3 Hz, 1H), 3.71 (s, 3H), 3.16-3.07 (m, 4H), 2.49-2.42 (m, 4H), 2.24 (s, 3H); ESI MS (m/z) 545 [M+H] + ; analytical HPLC t R =4.69 min.
Example 13
N-{4-[1-Methyl-4-(2-{[3-(4-methylpiperazin-1-yl)phenyl]amino}pyrimidin-4-yl)-1H-pyrazol-3-yl]phenyl}benzamide
[0112] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.36 (s, 1H), 9.31 (s, 1H), 8.30 (d, J=5.3 Hz, 1H), 8.16 (s, 1H), 7.99-7.95 (m, 2H), 7.86-7.82 (m, 2H), 7.61-7.49 (m, 5H), 7.40 (t, J=2.0 Hz, 1H), 7.20-7.14 (m, 1H), 7.03 (t, J=8.1 Hz, 1H), 6.57 (d, J=5.3 Hz, 1H), 6.53-6.46 (m, 1H), 3.96 (s, 3H), 3.12-3.07 (m, 4H), 2.48-2.43 (m, 4H), 2.23 (s, 3H); ESI MS (m/z) 545 [M+H] + ; analytical HPLC t R =4.52 min.
Examples 14 & 15
[0113] These compounds were prepared following a procedure analogous to that outlined for Examples 2 and 3.
Example 14
N-{4-[1-Methyl-4-(2-{[3-(4-methylpiperazin-1-yl)phenyl]amino}pyrimidin-4-yl)-1H-pyrazol-5-yl]phenyl}cyclopropanecarboxamide
[0114] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.45 (s, 1H), 9.28 (s, 1H), 8.20-8.16 (m, 1H), 8.08 (s, 1H), 7.79 (d, J=8.8 Hz, 2H), 7.44-7.38 (m, 3H), 7.13-7.08 (m, 1H), 7.04 (t, J=8.1 Hz, 1H), 6.54-6.50 (m, 1H), 6.24 (d, J=5.1 Hz, 1H), 3.68 (s, 3H), 3.14-3.08 (m, 4H), 2.49-2.41 (m, 4H), 2.23 (s, 3H), 1.88-1.79 (m, 1H), 0.88-0.80 (m, 4H); ESI MS (m/z) 509 [M+H] + ; analytical HPLC t R =4.07 min.
Example 15
N-{4-[1-Methyl-4-(2-{[3-(4-methylpiperazin-1-yl)phenyl]amino}pyrimidin-4-yl)-1H-pyrazol-3-yl]phenyl}cyclopropanecarboxamide
[0115] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.29 (s, 1H), 9.30 (s, 1H), 8.28 (d, J=5.3 Hz, 1H), 8.17 (s, 1H), 7.63 (d, J=8.6 Hz, 2H), 7.45-7.38 (m, 3H), 7.15 (d, J=9.1 Hz, 1H), 7.01 (t, J=8.1 Hz, 1H), 6.54 (d, J=5.0 Hz, 1H), 6.51 (dd, J=8.0, 1.9 Hz, 1H), 3.94 (s, 3H), 3.12-3.04 (m, 4H), 2.48-2.42 (m, 4H), 2.23 (s, 3H), 1.81-1.77 (m, 1H), 0.86-0.77 (m, 4H); ESI MS (m/z) 509 [M+H] + ; analytical HPLC t R =4.25 min.
Examples 16 & 17
[0116] These compounds were prepared following a procedure analogous to that outlined for Examples 2 and 3.
Example 16
N-{4-[1-Ethyl-4-(2-{[3-(4-methyl-1-piperazinyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-5-yl]phenyl}cyclopropanecarboxamide
[0117] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.47 (s, 1H), 9.27 (s, 1H), 8.17 (s, 1H), 8.12 (s, 1H), 7.80 (d, J=8.6 Hz, 2H), 7.46-7.36 (m, 3H), 7.14-7.11 (m, 1H), 7.05 (t, J=8.1 Hz, 1H) 6.52 (dd, J=7.8, 1.8 Hz, 1H), 6.18 (d, J=5.3 Hz, 1H), 3.95 (q, J=7.3 Hz, 2H), 3.14-3.05 (m, 4H), 2.50-2.46 (m, 4H), 2.24 (s, 3H), 1.84-1.82 (m, 1H), 1.26 (t, J=7.2 Hz, 3H), 0.87-0.79 (m, 4H); ESI MS (m/z) 523 [M+H] + ; analytical HPLC t R =4.53 min.
Example 17
N-{4-[1-Ethyl-4-(2-{[3-(4-methylpiperazin-1-yl)phenyl]amino}pyrimidin-4-yl)-1H-pyrazol-3-yl]phenyl}cyclopropanecarboxamide
[0118] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.29 (s, 1H), 9.30 (s, 1H), 8.29-8.26 (m, 1H), 8.15 (s, 1H), 7.63 (d, J=8.6 Hz, 2H), 7.46-7.40 (m, 3H), 7.12 (d, J=9.1 Hz, 1H), 7.00 (t, J=8.2 Hz, 1H), 6.55 (d, J=5.0 Hz, 1H), 6.51 (dd, J=8.3, 1.8 Hz, 1H), 4.03 (q, J=7.1 Hz, 2H), 3.12-3.06 (m, 4H), 2.48-2.39 (m, 4H), 2.23 (s, 3H), 1.83-1.76 (m, 1H), 1.18 (t, J=7.1 Hz, 3H), 0.87-0.77 (m, 4H); ESI MS (m/z) 523 [M+H] + ; analytical HPLC t R =4.33 min.
Example 18
N-(4-{4-[2-({3-[2-(4-Morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)-1-pyrrolidinecarboxamide
[0119] This compound was prepared following a procedure analogous to that outlined for Example 1. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 13.30 (s, 1H), 9.41 (s, 1H), 8.28 (d, J=5.0 Hz, 1H), 8.17 (s, 1H), 7.65-7.60 (m, 3H), 7.50-7.48 (m, 1H), 7.40 (d, J=8.6 Hz, 2H), 7.09 (t, J=7.8 Hz, 1H), 6.77 (d, J=7.6 Hz, 1H), 6.61 (d, J=5.3 Hz, 1H), 3.54-3.62 (m, 4H), 3.41-3.33 (m, 4H), 2.68-2.63 (m, 2H), 2.50-2.46 (m, 2H), 2.44-2.40 (m, 4H), 1.91-1.83 (m, 4H); ESI MS (m/z) 539 [M+H] + ; analytical HPLC t R =4.03 min.
Example 19
N-{4-[4-(2-{[3-(4-Methyl-1-piperazinyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}-1-pyrrolidinecarboxamide
[0120] This compound was prepared following a procedure analogous to that outlined for Example 1. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 13.26 (s, 1H), 9.30 (s, 1H), 8.26 (d, J=5.3 Hz, 1H), 8.18-8.14 (m, 1H), 7.63-7.60 (m, 2H), 7.47-7.42 (m, 1H), 7.39 (d, J=8.6 Hz, 2H), 7.19-7.16 (m, 1H), 7.03 (t, J=8.1 Hz, 1H), 6.57 (d, J=5.0 Hz, 1H), 6.51 (dd, J=8.1, 2.0 Hz, 1H), 3.41-3.36 (m, 4H), 3.14-3.06 (m, 4H), 2.49-2.43 (m, 4H), 2.23 (s, 3H), 1.89-1.83 (m, 4H); ESI MS (m/z) 524 [M+H] + ; analytical HPLC t R =4.00 min.
Example 20 & 21
[0121] These compounds were prepared following a procedure analogous to that outlined for Examples 2 and 3.
Example 20
N-(4-{1-Ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)-1-pyrrolidinecarboxamide
[0122] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 9.40 (s, 1H), 8.39 (s, 1H), 8.17 (d, J=5.3 Hz, 1H), 8.13 (s, 1H), 7.75 (d, J=8.6 Hz, 2H), 7.67 (s, 1H), 7.50 (d, J=8.3 Hz, 1H), 7.31 (d, J=8.8 Hz, 2H), 7.15 (t, J=7.8 Hz, 1H), 6.80 (s, 1H), 6.19 (d, J=5.3 Hz, 1H), 3.96 (q, J=7.1 Hz, 2H), 3.62-3.51 (m, 4H), 3.44-3.38 (m, 4H), 2.73-2.66 (m, 2H), 2.54-2.48 (m, 2H), 2.45-2.40 (m, 4H), 1.91-1.84 (m, 4H), 1.27 (t, J=7.3 Hz, 3H); ESI MS (m/z) 567 [M+H] + ; analytical HPLC t R =4.60 min.
Example 21
N-(4-{1-Ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}Phenyl)-1-pyrrolidinecarboxamide
[0123] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 9.41 (s, 1H), 8.29 (d, J=5.0 Hz, 1H), 8.21 (s, 1H), 8.17 (s, 1H), 7.61-7.53 (m, 3H), 7.49 (d, J=8.3 Hz, 1H), 7.37 (d, J=8.6 Hz, 2H), 7.10 (t, J=7.8 Hz, 1H), 6.77 (d, J=7.6 Hz, 1H), 6.58 (d, J=5.3 Hz, 1H), 4.23 (q, J=7.2 Hz, 2H), 3.62-3.52 (m, 4H), 3.40-3.33 (m, 4H) 2.70-2.63 (m, 2H), 2.50-2.47 (m, 2H), 2.44-2.40 (m, 4H), 1.91-1.82 (m, 4H), 1.46 (t, J=7.3 Hz, 3H); ESI MS (m/z) 567 [M+H] + ; analytical HPLC t R =4.45 min.
Intermediate 7
Ethyl 4-({[tert-butyloxy]carbonyl}amino)benzoate
[0124] This compound was prepared as described by Niimi et al. (Niimi, Tatsuya; Orita, Masaya; Okazawa-Igarashi, Miwa; Sakashita, Hitoshi; Kikuchi, Kazumi; Ball, Evelyn; Ichikawa, Atsushi; Yamagiwa, Yoko; Sakamoto, Shuichi; Tanaka, Akihiro; Tsukamoto, Shinichi; Fujita, Shigeo; Tatsuta, Kuniaki; Maeda, Yasuhide; Chikauchi, Ken., J. Med. Chem. 2001, 44(26), 4737-4740), with the following modification in work-up. The crude mixture was concentrated to dryness and redissolved in ethyl acetate. It was then washed with 1N HCl solution (3×) and dried over MgSO 4 . After filtration and full evaporation of the solvent, the crude crystals were washed with hexanes and dried under vacuum to give white crystals. 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.80 (s, 1H), 7.85 (d, J=8.8 Hz, 2H), 7.58 (d, J=8.8 Hz, 2H), 4.25 (q, J=7.2 Hz, 2H), 1.49 (s, 9H), 1.30 (t, J=7.2 Hz, 3H); ESI MS (m/z) 266 [M+H] + ; analytical HPLC t R =7.0 min.
Intermediate 8
tert-Butyl (4-{[2-(methylthio)-4-pyrimidinyl]acetyl}phenyl)carbamate
[0125] The title compound was prepared following the procedure of Intermediate 3, using ethyl 4-({[tert-butyloxy]carbonyl}amino)benzoate (Intermediate 7) as the ester. In the work-up, a cold solution of ammonium chloride was used instead of the hydrochloric acid solution, in order to avoid deprotection of the Boc group. ESI MS (m/z) 360 [M+H] + ; LC MS retention time t R =2.3 min (ketone) and t R =2.8 min (enol).
Intermediate 9
tert-Butyl {4-[4-(2-Methylsulfanyl-pyrimidin-4-yl)-1H-pyrazol-3-yl]-phenyl}carbamate
[0126] The title compound was prepared following the procedure of Intermediate 4, using Intermediate 8 as substrate. As modifications of the original procedure, formation of the activated eneamine in dimethylformamide dimethylacetal was achieved at 60° C. for 3 h, followed by 7 hours at room temperature. Purification involved flash column chromatography on silica gel, with a gradient of 10:90 to 30:70 AcOEt/Hexanes. 1 H NMR (400 MHz, DMSO-d 6 ) δ 13.25 (bs, 1H), 9.54 (s, 1H), 8.41 (d, J=5.2 Hz, 1H), 8.27 (s, 1H), 7.53 (d, J=8.8 Hz, 2H), 7.41 (d, J=8.8 Hz, 2H), 7.03 (d, J=5.2 Hz, 1H), 2.32 (s, 3H), 1.49 (s, 9H); ESI MS (m/z) 384 [M+H] + ; LCMS retention time t R =2.2 min; analytical HPLC t R =6.1 min.
Intermediate 10
tert-Butyl {4-[4-(2-Methanesulfonyl-pyrimidin-4-yl)-1H-pyrazol-3-yl]-phenyl}carbamate
[0127] To a solution of intermediate 9 (1.0 g) in 20 mL of a 1:1 THF/MeOH mixture cooled to 0° C. was added dropwise an aqueous solution of Oxone® (6.4 g in 20 mL of water). After 15 min, the reaction was warmed up to room temperature and stirred for an additional hour. Disappearance of starting material and intermediate sulfoxide was followed by HPLC. The mixture was then diluted with 60 mL of a saturated bicarbonate solution, and extracted with ethyl acetate (3×). The organic layers were combined, dried over MgSO 4 , and concentrated under vacuum. The compound was purified by flash chromatography on silica gel (gradient of CHCl 3 /MeOH/NH 4 OH from 100:0:0 to 90:10:1). ESI MS (m/z) 416 [M+H] + ; LCMS retention time t R =1.8 min; analytical HPLC t R (sulfone)=5.4 min.
Intermediate 11
Mixture of tert-butyl (4-{1-ethyl-4-[2-(methylsulfonyl)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl) carbamate & tert-butyl (4-{1-ethyl-4-[2-(methylsulfonyl)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl carbamate
[0128] The title compounds were prepared following the procedure of Example 6, using intermediate 10 as substrate and iodoethane as alkylating agent. 1 H NMR (400 MHz, DMSO-d 6 ) (mixture (1:1) of 2 regioisomers) δ 9.62 & 9.58 (s, 1H), 8.82 & 8.77 (d, J=4-5 Hz, 1H), 8.66 & 8.36 (s, 1H), 7.66 & 7.53, (d, J=8.1 Hz, 2H), 7.44 & 7.36 (d, J=8.1 Hz, 2H), 4.25 & 3.96 (q, J=8.0 Hz, 2H), 3.25 & 3.08 (s, 3H), 1.51 & 1.50 (s, 9H), 1.42 & 1.26 (t, J=8.0 Hz, 3H); ESI MS (m/z) 444; LCMS retention time t R =2.1 min (broad); analytical HPLC t R =6.12 & 6.27 min.
Intermediate 12
Mixture of tert-butyl (4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl) carbamate & tert-butyl (4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl) carbamate
[0129] The title compounds were prepared following the procedure outlined for Examples 2 and 3, using Intermediate 11 as substrate. Purification was conducted on the Analogix system with a CHCl 3 /MeOH gradient. ESI MS (m/z) 570; LCMS retention time t R =1.9 min (broad); analytical HPLC t R =5.26 & 5.49 min.
Intermediate 13
Mixture of 4-[3-(4-aminophenyl)-1-ethyl-1H-pyrazol-4-yl]-N-{3-[2-(4-morpholinyl)ethyl]phenyl}-2-pyrimidinamine & 4-[5-(4-aminophenyl)-1-ethyl-1H-pyrazol-4-yl]-N-{3-[2-(4-morpholinyl)ethyl]phenyl}-2-pyrimidinamine
[0130] Boc deprotection of Intermediate 12 was successfully achieved by treatment with 20% trifluoroacetic acid in methylene chloride for 30 min. The reaction mixture was then concentrated to dryness and azeotroped with toluene. ESI MS (m/z) 470 [M+H] + ; analytical HPLC t R =3.50 & 3.80 min.
Examples 22 and 23
[0131] Intermediate 13 was dissolved in pyridine at 0° C., followed by addition of one equivalent of ethyl isocyanate. The reaction was then warmed up to room temperature and stirred for several hours. Disappearance of starting material was followed by HPLC. The reaction mixture was then diluted with water and ethyl acetate, washed with 1M HCl (3×) and a saturated solution of sodium bicarbonate. The organic layers were combined, concentrated under vacuum (60° C.). The residue was azeotroped three times with toluene. Crude compounds were there purified by preparative HPLC.
Example 22
N-ethyl-N′-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)urea
[0132] 1 H NMR (400 MHz, CD 3 OD) δ8.22 (s, 1H), 8.15 (bs, 1H), 8.10 (d, J=4.1 Hz, 1H), 7.69 (s, 1H), 7.62 (d, J=8.1 Hz, 2H), 7.48 (d, J=8.0 Hz, 1H), 7.31 (d, J=8.1 Hz, 2H), 7.27 (t, J=8.0 Hz, 1H), 6.94 (d, J=7.9 Hz, 1H), 6.33 (d, J=8.0 Hz, 1H), 4.06 (q, J=4.0 Hz, 2H), 3.94 (bs, 2H), 3.42-3.35 (m, 6H), 3.28 (q, J=4.0 Hz, 2H), 3.10-3.06 (m, 2H), 1.35 (t, J=4.0 Hz, 3H), 1.20 (t, J=4.0 Hz, 3H); ESI MS (m/z) 541 [M+H] + ; LCMS retention time t R =1.47 min; analytical HPLC t R =4.35 min.
Example 23
N-ethyl-N′-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)urea
[0133] 1 H NMR (400 MHz, CD 3 OD) δ8.25 (s, 1H); 8.24 (d, J=4.1 Hz, 1H), 8.09 (bs, 1H), 7.54 (s, 1H), 7.48 (d, J=8.1 Hz, 2H), 7.41 (m, 3H), 7.24 (t, J=8.0 Hz, 1H), 6.91 (d, J=7.9 Hz, 1H), 6.75 (d, J=8.0 Hz, 1H), 4.28 (q, J=4.0 Hz, 2H), 3.94 (bs, 2H), 3.40-3.30 (m, 6H), 3.14 (q, J=4.0 Hz, 2H), 3.01-2.96 (m, 2H), 1.56 (t, J=4.0 Hz, 3H), 1.19 (t, J=4.0 Hz, 3H); ESI MS (m/z) 541 [M+H] + ; LCMS retention time t R =1.48 min; analytical HPLC t R =4.16 min.
Examples 24 and 25
[0134] These compounds were prepared following a procedure analogous to the one outlined for Examples 22 and 23, using Intermediate 13 and n-propyl isocyanate as reagents.
Example 24
N-propyl-N′-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)urea
[0135] ESI MS (m/z) 555 [M+H] + ; LCMS retention time t R =1.52 min; analytical HPLC t R =4.54 min.
Example 25
N-propyl-N′-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)urea
[0136] 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.42 (s, 1H), 8.53 (s, 1H), 8.29 (d, J=4.0 Hz, 1H), 8.26 (s, 1H), 8.14 (bs, 2H), 7.59 (s, 1H), 7.47 (d, J=12.1 Hz, 1H), 7.42 (d, J=8.1 Hz, 2H), 7.36 (d, J=8.1 Hz, 2H), 7.09 (t, J=8.0 Hz, 1H), 6.77 (d, J=8.0 Hz, 1H), 6.58 (d, J=4.0 Hz, 1H), 6.18 (t, J=4.0 Hz, 1H), 5.75 (m, 2H), 4.22 (q, J=4.0 Hz, 2H), 3.60 (m, 4H), 3.05 (q, J=4.1 Hz, 2H), 2.92 (q, J=4.0 Hz, 4H), 2.70-2.65 (m, 2H), 1.49-1.43 (m, 5H), 0.88 (t, J=4.0 Hz, 3H); ESI MS (m/z) 555 [M+H] + ; LCMS retention time t R =1.50 min; analytical HPLC t R =4.39 min.
Examples 26 and 27
[0137] To a solution of 50 mg of Intermediate 13 in THF was added dropwise a 20% phosgene solution in toluene (1 equivalent). The reaction mixture was stirred at 0° C. for 30 min, before addition of cyclopropylamine (2 equivalents). The reaction was warmed up to room temperature and stirred for an additional hour. Disappearance of starting material was followed by HPLC. The reaction was then diluted with water and ethyl acetate. After decantation, aqueous layer was extracted three times with AcOEt. The organic layers were combined, dried over MgSO 4 and concentrated under vacuum. Crude compounds were there purified by preparative HPLC.
Example 26
N-cyclopropyl-N′-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)urea
[0138] 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.53 (s, 1H), 8.63 (s, 1H), 8.19 (d, J=4.0 Hz, 1H), 8.15 (s, 1H), 7.73 (s, 1H), 7.62 (d, J=8.1 Hz, 2H), 7.55 (d, J=12.1 Hz, 1H), 7.30 (d, J=8.1 Hz, 2H), 7.23 (t, J=8.0 Hz, 1H), 6.84 (d, J=8.0 Hz, 1H), 6.54 (m, 1H), 6.22 (d, J=4.0 Hz, 1H), 4.03 (d, J=12.0 Hz, 2H), 3.95 (q, J=8.0 Hz, 2H), 3.54 (m, 2H); 3.15 (m, 1H), 2.97 (m, 1H), 1.27 (t, J=8.0 Hz, 3H), 1.27 (m, 1H), 0.67 (m, 2H), 0.43 (m, 2H); ESI MS (m/z) 553 [M+H] + ; LCMS retention time t R =1.52 min; analytical HPLC t R =4.35 min.
Example 27
N-cyclopropyl-N′-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)urea
[0139] 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.53 (s, 1H), 8.42 (s, 1H), 8.31 (d, J=4.0 Hz, 1H), 8.29 (s, 1H), 7.62 (s, 1H), 7.53 (d, J=12.1 Hz, 1H), 7.44 (d, J=8.1 Hz, 2H), 7.38 (d, J=8.1 Hz, 2H), 7.17 (t, J=8.0 Hz, 1H), 6.81 (d, J=8.0 Hz, 1H), 6.63 (d, J=4.0 Hz, 1H), 6.44 (m, 1H), 4.23 (q, J=8.0 Hz, 2H), 4.02 (d, J=12.0 Hz, 2H), 3.66 (t, J=12.0 Hz, 2H), 3.52 (d, J=12.0 Hz, 2H), 2.89 (m, 1H), 2.67 (m, 1H), 2.55 (m, 1H), 2.33 (m, 1H), 1.46 (t, J=8.0 Hz, 3H), 1.24 (m, 1H), 0.64 (m, 2H), 0.41 (m, 2H); ESI MS (m/z) 553 [M+H] + ; LCMS retention time tR=1.48 min; analytical HPLC tR=4.23 min.
[0140] Examples 28-53 were prepared following procedures analogous to that outlined for Examples 26 & 27.
Example 28
N-(4-{1-(1-methylethyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0141] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.28 (s, 1H), 9.42 (s, 1H), 8.32-8.28 (m, 2H), 7.63 (d, J=8.59 Hz, 2H), 7.59 (s, 1H), 7.44 (d, J=8.84 Hz, 2H), 7.07-7.05 (m, 2H), 6.77 (s, 1H), 6.62 (d, J=5.05 Hz, 1H), 4.64-4.55 (m, 1H), 4.12-4.10 (m, 2H), 3.67-3.65 (m, 4H), 3.35-3.33 (m, 4H), 3.17 (d, J=5.31 Hz, 2H), 1.80-1.78 (m, 1H), 1.50 (d, J=6.82 Hz, 6H), 0.81-0.79 (m, 4H); ESI MS (m/z) 552 [M+H] + ; LCMS retention time t R =1.58 min: analytical HPLC t R =4.63 min.
Example 29
N-(4-{1-(1-methylethyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)cyclopropanecarboxamide
[0142] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.48 (s, 1H), 9.52 (s, 1H), 8.20-8.16 (m, 2H), 7.81 (d, J=8.59 Hz, 2H), 7.73 (s, 1H), 7.52-7.51 (m, 1H), 7.37 (d, J=8.59 Hz, 2H), 7.23-7.22 (m, 1H), 6.86-6.85 (m, 1H), 6.17 (d, J=5.31 Hz, 1H), 4.26-4.24 (m, 1H), 4.03-4.00 (m, 2H), 3.65-3.48 (m, 4H), 3.15-2.95 (m, 4H), 2.45-2.43 (m, 2H), 1.84-1.83 (m, 1H), 1.36 (d, J=6.57 Hz, 6H), 0.84 (d, J=6.06 Hz, 4H); ESI MS (m/z) 552: LCMS retention time t R =1.60 min: analytical HPLC t R =4.77 min.
Example 30
N-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0143] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.29 (s, 1H), 8.32-8.30 (m, 2H), 8.14 (s, 1H), 7.62 (d, J=8.84 Hz, 2H), 7.58 (s, 1H), 7.44 (d, J=8.59 Hz, 2H), 7.10-7.09 (m, 1H), 6.79-6.78 (m, 1H), 6.62-6.60 (m, 1H), 4.11 (t, J=5.05 Hz, 2H), 3.60-3.50 (m, 4H), 3.39-3.30 (m, 4H), 3.20-3.18 (m, 2H), 2.50-2.46 (m, 2H), 1.81-1.78 (s, 1H), 1.46 (t, J=7.33 Hz, 3H), 0.82-0.79 (m, 4H); ESI MS (m/z) 538: LCMS retention time t R =1.50 min: analytical HPLC t R =4.35 min.
Example 31
N-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)cyclopropanecarboxamide
[0144] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.47 (s, 1H), 9.52 (s, 1H), 8.20-8.15 (m, 2H), 7.81 (d, J=8.84 Hz, 1H), 7.70 (s, 1H), 7.52-7.51 (m, 1H), 7.38 (d, J=8.59 Hz, 2H), 7.24-7.22 (m, 1H), 6.84-6.83 (m, 1H), 6.23-6.22 (m, 1H), 4.00-3.92 (m, 2H), 3.66-3.44 (m, 6H), 3.17-2.90 (m, 4H), 2.51-2.33 (m, 2H), 1.84-1.82 (m, 1H), 1.27 (t, J=7.20 Hz, 3H), 0.85-0.84 (m, 4H); ESI MS (m/z) 538: LCMS retention time t R =1.60 min: analytical HPLC t R =4.53 min.
Example 32
N-(4-{1-(2-hydroxyethyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0145] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.29 (s, 1H), 9.45 (s, 1H), 8.30 (d, J=5.05 Hz, 1H), 8.26 (s, 1H), 7.63 (d, J=8.84 Hz, 2H), 7.60-7.58 (m, 1H), 7.50-7.48 (s, 1H), 7.44 (d, J=8.84 Hz, 2H), 7.08-7.07 (m, 1H), 6.79-6.78 (m, 1H), 6.59 (d, J=5.05 Hz, 1H), 4.24 (t, J=5.43 Hz, 2H), 3.81 (t, J=5.18 Hz, 2H), 3.62-3.58 (m, 4H), 3.39-3.32 (m, 2H), 2.68-2.67 (m, 2H), 2.51-2.33 (m, 4H), 1.79-1.76 (m, 1H), 0.85-0.76 (m, 4H); ESI MS (m/z) 554: LCMS retention time t R =1.37 min: analytical HPLC t R =3.85 min.
Example 33
N-(4-{1-[2-(methyloxy)ethyl]-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0146] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.29 (s, 1H), 9.43 (s, 1H), 8.30 (d, J=5.31 Hz, 1H), 8.25 (s, 1H), 7.63 (d, J=8.59 Hz, 2H), 7.55 (s, 1H), 7.47 (d, J=10.61 Hz, 1H), 7.46-7.42 (m, 2H), 7.07 (t, J=7.83 Hz, 1H), 6.77 (d, J=7.58 Hz, 1H), 6.59 (d, J=5.31 Hz, 1H), 4.36 (t, J=5.18 Hz, 2H), 3.76 (t, J=5.18 Hz, 2H), 3.62-3.56 (m, 4H), 3.43-3.30 (m, 2H), 3.28 (s, 3H), 3.19-3.16 (m, 4H), 2.69-2.63 (m, 2H), 1.84-1.75 (m, 1H), 0.86-0.77 (m, 4H); ESI MS (m/z) 568: LCMS retention time t R =1.53 min: analytical HPLC t R =4.08 min.
Example 34
N-(4-{1-[2-(methyloxy)ethyl]-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)cyclopropanecarboxamide
[0147] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.46 (s, 1H), 9.42 (s, 1H), 8.19 (d, J=5.31 Hz, 1H), 8.16-8.13 (m, 1H), 7.79 (d, J=8.59 Hz, 2H), 7.64 (s, 1H), 7.46 (d, J=7.83 Hz, 1H), 7.37 (d, J=8.84 Hz, 2H), 7.13 (t, J=7.96 Hz, 1H), 6.79 (d, J=7.58 Hz, 1H), 6.21 (d, J=5.31 Hz, 1H), 4.09-4.06 (m, 2H), 3.69-3.58 (m, 2H), 3.34-3.25 (m, 8H), 3.17 (s, 3H), 2.72-2.54 (m, 4H), 0.86-0.84 (m, 1H), 0.84-0.82 (m, 4H); ESI MS (m/z) 568: LCMS retention time t R =1.57 min: analytical HPLC t R =4.37 min.
Example 35
N-(4-{1-(2-methylpropyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0148] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.29 (s, 1H), 9.42 (s, 1H), 8.30 (d, J=5.31 Hz, 1H), 8.25 (s, 1H), 7.63 (d, J=8.84 Hz, 2H), 7.58 (s, 1H), 7.45-7.43 (m, 3H), 7.06 (t, J=7.83 Hz, 1H), 6.76 (d, J=7.58 Hz, 1H), 6.60 (d, J=5.05 Hz, 1H), 4.11 (d, J=5.05 Hz, 2H), 4.01 (d, J=7.07 Hz, 2H), 3.62-3.54 (m, 4H), 3.17-3.15 (m, 4H), 2.69-2.44 (m, 2H), 2.25-2.14 (m, 1H), 1.83-1.75 (m, 1H), 0.91 (d, J=6.82 Hz, 6H), 0.86-0.76 (m, 4H); ESI MS (m/z) 566: LCMS retention time t R =1.71 min: analytical HPLC t R =4.28 min.
Example 36
N-(4-{1-(2-methylpropyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)cyclopropanecarboxamide
[0149] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.47 (s, 1H), 8.19-8.12 (m, 2H), 7.80 (d, J=8.59 Hz, 2H), 7.68 (s, 1H), 7.52-7.50 (m, 1H), 7.35 (d, J=8.59 Hz, 2H), 7.21-7.19 (m, 1H), 6.84-6.82 (m, 1H), 6.19 (d, J=5.31 Hz, 1H), 4.10-4.01 (m, 2H), 4.78-4.76 (m, 4H), 3.66-3.60 (m, 4H), 3.30-3.17 (m, 4H), 2.10-1.99 (m, 1H), 1.86-1.78 (m, 1H), 0.84 (d, J=6.06 Hz, 4H), 0.73 (d, J=6.82 Hz, 6H); ESI MS (m/z) 566: LCMS retention time t R =1.72 min: analytical HPLC t R =5.11 min.
Example 37
N-(4-{1-(methylsulfonyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0150] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.36 (s, 1H), 9.54 (s, 1H), 8.72 (s, 1H), 8.45 (d, J=5.05 Hz, 1H), 7.68 (d, J=8.84 Hz, 2H), 7.52 (d, J=8.59 Hz, 2H), 7.47 (s, 1H), 7.30 (s, 1H), 7.00 (t, J=7.96 Hz, 1H), 6.81 (d, J=5.05 Hz, 1H), 6.76 (d, J=7.58 Hz, 1H), 3.70 (s, 3H), 3.61-3.55 (m, 4H), 3.18-3.16 (s, 2H), 2.64-2.28 (m, 6H), 1.82-1.76 (m, 1H), 0.85-0.77 (m, 4H); ESI MS (m/z) 588: LCMS retention time t R =1.73 min: analytical HPLC t R =4.76 min.
Example 38
N-(4-{1-(2-hydroxyethyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)cyclopropanecarboxamide
[0151] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.47 (s, 1H), 9.51 (s, 1H), 8.25-8.13 (m, 2H), 7.79 (d, J=8.84 Hz, 2H), 7.69 (s, 1H), 7.51-7.50 (m, 1H), 7.40 (d, J=8.59 Hz, 2H), 7.21-7.19 (m, 1H), 6.85-6.84 (s, 1H), 6.22 (d, J=5.31 Hz, 1H), 4.12-3.96 (m, 2H), 3.74-3.53 (m, 6H), 3.17-2.97 (m, 6H), 2.57-2.53 (m, 2H), 1.86-1.79 (m, 1H), 0.84 (d, J=6.06 Hz, 4H); ESI MS (m/z) 554: LCMS retention time t R =1.43 min: analytical HPLC t R =3.89 min.
Example 39
N-(4-{4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1-[2-oxo-2-(1-pyrrolidinyl)ethyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0152] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.29 (s, 1H), 9.43 (s, 1H), 8.35-8.28 (m, 2H), 7.63 (d, J=8.59 Hz, 2H), 7.54 (s, 1H), 7.44 (d, J=8.59 Hz, 2H), 7.08-7.06 (m, 1H), 6.78-6.77 (m, 1H), 6.59 (d, J=5.30 Hz, 1H), 5.15 (s, 2H), 3.60-3.17 (m, 10H), 2.38-2.33 (m, 6H), 1.95-1.93 (m, 1H), 1.85-1.74 (m, 4H), 0.85-0.78 (m, 4H); ESI MS (m/z) 621: LCMS retention time t R =1.56 min: analytical HPLC t R =4.24 min.
Example 40
N-{4-[4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1-(2,2,2-trifluoroethyl)-1H-pyrazol-3-yl]phenyl}cyclopropanecarboxamide
[0153] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.32 (s, 1H), 9.49 (s, 1H), 8.39 (s, 1H), 8.34 (d, J=5.31 Hz, 1H), 7.65 (d, J=8.59 Hz, 2H), 7.53 (s, 1H), 7.48-7.43 (m, 3H), 7.07 (t, J=7.83 Hz, 1H), 6.77 (d, J=7.58 Hz, 1H), 6.60 (d, J=5.31 Hz, 1H), 5.29 (q, J=9.09 Hz, 2H), 3.58-3.53 (m, 4H), 2.68-2.60 (m, 2H), 2.49-2.40 (m, 6H), 1.83-1.75 (m, 1H), 0.84-0.76 (m, 4H); ESI MS (m/z) 592: LCMS retention time t R =1.65 min: analytical HPLC t R =4.85 min.
Example 41
3-{4-[(cyclopropylcarbonyl)amino]phenyl}-N-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazole-1-carboxamide
[0154] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.35 (s, 1H), 9.51 (s, 1H), 8.75 (s, 1H), 8.70 (t, J=6.06 Hz, 1H), 8.39 (d, J=5.05 Hz, 1H), 7.68 (d, J=8.59 Hz, 2H), 7.56-7.54 (m, 3H), 7.36 (d, J=7.07 Hz, 1H), 7.04 (t, J=7.83 Hz, 1H), 6.76 (d, J=7.58 Hz, 1H), 6.73 (d, J=5.31 Hz, 1H), 3.60-3.52 (m, 4H), 3.39-3.28 (m, 2H), 2.68-2.58 (m, 2H), 2.50-2.33 (m, 6H), 1.79 (t, J=6.06 Hz, 1H), 1.16 (t, J=7.07 Hz, 3H), 0.85-0.77 (m, 4H); ESI MS (m/z) 581: LCMS retention time t R =1.71 min: analytical HPLC t R =4.97 min.
Example 42
N-(4-{1-(3-hydroxypropyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0155] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.29 (s, 1H), 9.42 (s, 1H), 8.30 (d, J=5.05 Hz, 1H), 8.26 (s, 1H), 7.63 (d, J=8.84 Hz, 2H), 7.56 (s, 1H), 7.47-7.42 (m, 3H), 7.06 (t, J=7.83 Hz, 2H), 6.76 (d, J=7.58 Hz, 1H), 6.60 (d, J=5.31 Hz, 1H), 4.26 (t, J=6.95 Hz, 2H), 3.63-3.53 (m, 4H), 3.48-3.40 (m, 2H), 3.17-3.16 (m, 2H), 2.69-2.60 (m, 2H), 2.50-2.44 (m, 4H), 2.04-1.95 (m, 2H), 1.82-1.75 (m, 1H), 0.84-0.76 (m, 4H); ESI MS (m/z) 568: LCMS retention time t R =1.41 min: analytical HPLC t R =3.95 min.
Example 43
N-(4-{1-(3-hydroxypropyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)cyclopropanecarboxamide
[0156] 1 H NMR (400 MHz, DMSO- d6 ) δ ppm 10.48 (s, 1H), 9.40 (s, 1H), 8.32-8.25 (m, 1H), 8.18 (d, J=5.05 Hz, 1H), 7.79 (d, J=8.59 Hz, 2H), 7.64 (s, 1H), 7.46-7.45 (m, 1H), 7.37 (d, J=8.59 Hz, 2H), 7.12 (t, J=7.83 Hz, 1H), 6.78 (d, J=7.58 Hz, 1H), 6.19 (d, J=5.31 Hz, 1H), 4.03-3.92 (m, 2H), 3.62-3.53 (m, 4H), 3.34 (t, J=6.06 Hz, 2H), 3.18-3.17 (m, 2H), 2.74-2.63 (m, 2H), 2.50-2.43 (s, 4H), 1.89-1.79 (m, 3H), 0.85-0.83 (m, 4H); ESI MS (m/z) 568: LCMS retention time t R =1.41 min: analytical HPLC t R =3.99 min.
Example 44
N-(4-{1-[(2S)-2,3-dihydroxypropyl]-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0157] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.31 (s, 1H), 9.43 (s, 1H), 8.30-8.28 (m, 1H), 8.23 (s, 1H), 7.65-7.62 (m, 2H), 7.57 (s, 1H), 7.48-7.43 (m, 3H), 7.08-7.04 (m, 1H), 6.77-6.75 (m, 1H), 6.58-6.57 (m, 1H), 4.30-4.28 (m, 1H), 4.07-4.03 (m, 1H), 3.89-3.87 (m, 1H), 3.60-3.18 (m, 8H), 2.67-2.63 (m, 2H), 2.50-2.33 (m, 4H), 1.80-1.79 (m, 1H), 0.81-0.79 (m, 4H); ESI MS (m/z) 584: LCMS retention time t R =1.31 min: analytical HPLC t R =3.73 min.
Example 45
N-(4-{1-[(2R)-2,3-dihydroxypropyl]-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)cyclopropanecarboxamide
[0158] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.30 (s, 1H), 9.44 (s, 1H), 8.30-2.28 (m, 2H), 7.64 (d, J=8.59 Hz, 2H), 7.57 (s, 1H), 7.49-7.42 (m, 3H), 7.07 (t, J=7.71 Hz, 1H), 6.76 (d, J=7.58 Hz, 1H), 6.58 (d, J=5.05 Hz, 1H), 4.32 (dd, J=13.89, 3.54 Hz, 1H), 4.06 (dd, J=13.89, 8.08 Hz, 1H), 3.87-3.76 (m, 1H), 3.66-3.17 (m, 6H), 2.68-2.62 (m, 2H), 2.51-2.46 (m, 6H), 1.84-1.74 (m, 1H), 0.84-0.75 (m, 4H); ESI MS (m/z) 584: LCMS retention time t R =1.27 min: analytical HPLC t R =3.72 min.
Example 46
N-(4-{1-(3-hydroxy propyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)-1-pyrrolidinecarboxamide
[0159] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 9.41 (m, 1H), 8.29 (d, J=5.31 Hz, 1H), 8.26-8.17 (m, 3H), 7.63-7.54 (m, 3H), 7.50-7.48 (m, 1H), 7.37 (d, J=8.59 Hz, 2H), 7.09 (t, J=7.96 Hz, 1H), 6.77 (d, J=7.58 Hz, 1H), 6.58 (d, J=5.05 Hz, 1H), 4.25 (t, J=7.07 Hz, 2H), 3.66-3.17 (m, 12H), 3.59-3.55 (m, 2H), 2.59-2.40 (m, 4H), 2.05-1.95 (m, 2H), 1.82-1.91 (m, 4H); ESI MS (m/z) 597: LCMS retention time t R =1.47 min: analytical HPLC t R =3.77 min.
Example 47
N-(4-{1-[(2R)-2,3-dihydroxypropyl]-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)-1-pyrrolidinecarboxamide
[0160] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 9.44 (s, 1H), 8.29-8.20 (m, 2H), 7.60-7.56 (m, 3H), 7.50-7.48 (m, 1H), 7.40-7.33 (m, 2H), 7.10 (t, J=7.83 Hz, 1H), 6.79-6.77 (m, 1H), 6.56 (d, J=5.31 Hz, 1H), 4.33-4.28 (m, 1H), 4.06-4.05 (m, 1H), 3.99-3.89 (m, 1H), 3.66-3.16 (m, 12H), 2.70-2.62 (m, 2H), 2.50-2.33 (m, 4H), 1.91-1.84 (m, 4H); ESI MS (m/z) 613: LCMS retention time t R =2.07 min: analytical HPLC t R =3.76 min.
Example 48
N-(4-{1-[(2S)-2,3-dihydroxypropyl]-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)-1-pyrrolidinecarboxamide
[0161] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 9.44 (s, 1H), 8.29-8.22 (m, 3H), 7.61-7.57 (m, 3H), 7.51-7.49 (m, 1H), 7.37 (d, J=8.84 Hz, 2H), 7.12-7.08 (m, 1H), 6.79-6.77 (m, 1H), 6.57-6.58 (m, 1H), 4.35-4.30 (m, 1H), 4.10-4.04 (m, 1H), 3.90-3.85 (m, 1H), 3.61-3.29 (m, 12H), 2.69-2.65 (m, 2H), 2.51-2.33 (m, 4H), 1.91-1.83 (m, 4H); ESI MS (m/z) 613: LCMS retention time t R =1.32 min: analytical HPLC t R =3.78 min.
Example 49
N,N-diethyl-N′-{4-[1-(2-hydroxyethyl)-4-(2-{[3-(4-methyl-1-piperazinyl phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}urea
[0162] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.35 (s, 1H), 9.52 (s, 1H), 8.33-8.26 (m, 3H), 7.56 (d, J=8.84 Hz, 2H), 7.50 (s, 1H), 7.38 (d, J=8.59 Hz, 2H), 7.20-7.18 (m, 1H), 7.11 (t, J=8.08 Hz, 1H), 6.60-6.58 (m, 2H), 4.25 (t, J=5.18 Hz, 2H), 3.82 (t, J=5.31 Hz, 2H), 3.72-3.70 (m, 2H), 3.51-3.49 (m, 2H), 3.36 (q, J=7.07 Hz, 4H), 3.16 (d, J=11.62 Hz, 2H), 3.03-3.00 (m, 2H), 2.83 (d, J=4.80 Hz, 3H), 1.10 (t, J=7.07 Hz, 6H); ESI MS (m/z) 570: LCMS retention time t R =1.38 min: analytical HPLC t R =2.04 min.
Example 50
N′-{4-[1-(2-hydroxyethyl)-4-(2-{[3-(1-pyrrolidinylmethyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}-N,N-dimethylurea
[0163] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.33 (s, 1H), 9.75 (s, 1H), 8.42 (s, 1H), 8.38-8.31 (m, 1H) 7.92 (s, 1H), 7.61-7.59 (m, 1H), 7.53 (d, J=8.59 Hz, 2H), 7.38 (d, J=8.59 Hz, 2H), 7.29 (t, J=7.96 Hz, 1H), 7.15 (d, J=7.58 Hz, 1H), 6.66 (d, J=5.31 Hz, 1H), 4.28-4.19 (m, 2H), 3.82 (t, J=5.31 Hz, 2H) 3.64-3.57 (m, 2H), 3.41-3.33 (m, 2H), 3.02-3.03 (m, 2H) 2.94 (s, 6H), 2.02-2.00 (m, 2H), 1.88-1.85 (m, 2H); ESI MS (m/z) 527: LCMS retention time t R =1.30 min: analytical HPLC t R =1.84 min.
Example 51
N′-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)-N,N-dimethylurea
[0164] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.9 (bs, 1H), 9.75 (s, 1H), 8.43 (s, 1H), 8.35 (s, 1H), 8.32 (d, J=5.4 Hz, 2H), 7.70 (m, 1H), 7.60 (s, 1H), 7.52 (d, J=8.8 Hz, 2H), 7.49 (d, J=7.9 Hz, 1H), 7.38 (d, J=8.8 Hz, 2H), 7.19 (t, J=7.9 Hz, 1H), 6.85 (d, J=7.9 Hz, 1H), 6.66 (d, J=5.4 Hz, 2H), 4.23 (q, J=7.3 Hz, 2H), 3.98 (m, 2H), 3.79 (m, 2H), 3.50 (m, 2H), 1.76 (m, 2H), 1.46 (t, J=7.3 Hz, 3H), 0.88 (m, 2H). ESI MS (m/z) 541; HPLC (Method A) t R =5.72 min.
Example 52
N,N-diethyl-N′-{4-[1-methyl-4-(2-{[3-(1-pyrrolidinylmethyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}urea
[0165] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 9.46 (s, 1H), 8.29 (d, J=5.1 Hz, 1H), 8.25 (s, 1H), 7.68 (s, 1H), 7.56 (d, J=8.8 Hz, 1H), 7.55 (d, J=8.8 Hz, 2H), 7.37 (d, J=8.8 Hz, 2H), 7.14 (t, J=7.8 Hz, 1H), 6.86 (d, J=7.8 Hz, 1H), 6.59 (d, J=5.1 Hz, 1H), 3.94 (s, 3H), 3.58-3.66 (m, 2H), 3.50-3.58 (m, 2H), 3.39-3.33 (m, 2H), 3.36 (q, J=6.91 Hz, 4H), 1.74-1.81 (m, 2H), 1.67-1.73 (m, 3H), 1.10 (t, J=7.1 Hz, 6H); ESI MS (m/z) 525; HPLC (Method A but with gradient 5-95 over 5 min) t R =2.22 min.
Example 53
N,N-dimethyl-N′-{4-[1-methyl-4-(2-{[3-(1-pyrrolidinylmethyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}urea
[0166] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 9.62 (bs, 1H), 8.33 (d, J=5.3 Hz, 1H), 8.30 (s, 1H), 8.14 (s, 1H), 7.83 (s, 1H), 7.62 (d, J=7.8 Hz, 1H) 7.52 (d, J=8.6 Hz, 2H), 7.38 (d, J=8.6 Hz, 2H), 7.28 (t, J=7.8 Hz, 1H), 7.16 (d, J=7.8 Hz, 1H), 6.65 (d, J=5.3 Hz, 1H), 4.21 (d, J=5.3 Hz, 2H), 3.94 (m, 3H), 3.29-3.41 (m, 2H), 3.17 (s, 3H), 2.98-3.10 (m, 2H), 2.94 (s, 3H), 1.94-2.09 (m, 2H), 1.80-1.93 (m, 2H); ESI MS (m/z) 497; HPLC (Method A but with gradient 5-95 over 5 min) t R =2.14 min.
Intermediate 14
3-(4-nitrophenyl)-1H-pyrazole
[0167] In a 1000 ml flask under argon was dissolved 4-nitroacetaphenone (30.0 g, 0.182 mol) in 300 ml dry DMF. To this solution was added DMF-DMA (29.1 ml, 0.218 mol) and heat at 80° C. for 2 hours, after which time the reaction was concentrated to dryness under vacuum. The resulting dark solid was dissolved in 300 ml absolute ETOH and Hydrazine monohydrate (28.3 ml, 0.582 mol) was added. The resulting solution was heated at 75° C. for 1.5 hours, at which time the reaction was cooled to room temperature and poured onto 1500 ml ice water. The resulting yellow precipitate was filtered, washed with 2000 ml water, and dried under vacuum to yield 3-(4-nitrophenyl)-1H-pyrazole (31.6 g, 70% purity). This material was used as is in the next step.
Intermediate 15
1-methyl-3-(4-nitrophenyl)-1H-pyrazole
[0168] In a 1000 ml flask under argon was dissolved 3-(4-nitrophenyl)-1H-pyrazole (31.6 g, 0.167 mol) in 300 ml dry DMF. To this solution was added cesium carbonate (65.3 g, 0.200 mol) followed by iodomethane (22 ml, 0.351 mol). The reaction was stirred at room temperature overnight, after which time an additional 2 ml iodomethane was added to force reaction to completion. The reaction was carefully diluted with 600 ml water and the resulting tan solids were filtered, washed with 1500 ml water, 500 ml hexanes, and dried under vacuum to yield 1-methyl-3-(4-nitrophenyl)-1H-pyrazole (22.8 g, >95% pure).
Intermediate 16
4-bromo-1-methyl-3-(4-nitrophenyl)-1H-pyrazole
[0169] In a 1000 ml flask under argon was dissolved 1-methyl-3-(4-nitrophenyl)-1H-pyrazole (22.8 g, 0.112 mol) in 450 ml chloroform. To this solution was added bromine (8.7 ml, 0.169 mol) over 5 minutes with rapid stirring at room temperature, resulting in an orange precipitate. After 20 minutes, the mixture was poured into 1000 ml EtOAc (heterogeneous mixture) and washed with saturated aqueous 50/50 NaHCO3/Na2S2O3 (2×700 ml). The now homogeneous organic phase was then washed with brine, dried over Na2SO4, and concentrated under vacuum to ˜20% overall volume. The solution was diluted with 1000 ml hexanes resulting in the precipitation of 4-bromo-1-methyl-3-(4-nitrophenyl)-1H-pyrazole (29.0 g, >95% pure). 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.34-8.31 (m, 2H), 8.14-8.12 (m, 3H), 3.93 (s, 3H).
Intermediate 17
1-methyl-3-(4-nitrophenyl)-4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)-1H-pyrazole
[0170] In a 1000 ml flask fitted with a condenser was placed potassium acetate (31.2 g, 0.318 mol) which was then dried under hi-vac at 50° C. overnight. The following morning, 4-bromo-1-methyl-3-(4-nitrophenyl)-1H-pyrazole (30.0 g, 0.106 mol), bis(pinacolato)-diboron (29.7 g, 0.117 mol), and 250 ml 1,4-dioxane were added. The mixture was deoxygenated with bubbling nitrogen for 15 minutes. After adding dichloro-bis(triphenylphosphine)palladium(II) (3.72 g, 5.30 mmol) the reaction mixture was heated at 95° C. under argon for 3 hours, after which the reaction was concentrated under vacuum. The resulting brown solid was dissolved in 550 ml hot EtOH and treated with activated carbon for 30 minutes after which time it was hot filtered through a pad of Celite 545. The filtered solution was placed in a −20° C. freezer overnight, resulting in the crystallization of 1-methyl-3-(4-nitrophenyl)-4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)-1H-pyrazole (17.3 g, 89% pure). Further crystallizations of the mother liquor were unsuccessful, however reverse-phase prep HPLC (MeCN/H 2 O—C18) was able to isolate and additional 4.5 g of desired product. ESI MS m/z 330 [C 16 H 20 BN 3 O 4 +H] + .
[0171] The primary byproduct of this reaction is 1-methyl-3-(4-nitrophenyl)-1H-pyrazole.
Intermediate 18
2-chloro-4-[1-methyl-3-(4-nitrophenyl)-1H-pyrazol-4-yl]pyrimidine
[0172] A mixture of 17 (17 g, 52 mmol), 2,4-dichloropyrimidine (12 g, 78 mmol), and sodium carbonate (7.1 g, 67 mmol) in water (39 mL) and ethanol (200 mL) was degassed with argon for 30 minutes. Trans-dichlorobis (triphenylphosphine)palladium (II) (1.8 g, 2.6 mmol) was added and the slurry stirred vigorously under argon at 75° C. for 16 h. The solids formed in the reaction mixture were filtered and dissolved in hot tetrahydrofuran (2 L). This tetrahydrofuran solution was concentrated to 500 mL and the resulting slurry was allowed to sit overnight. The slurry was filtered to give 18 (6.7 g, 24% over 2 steps) as a tan solid: ESI MS m/z 316 [C 14 H 10 ClN 5 O 2 +H] + .
Intermediate 19
4-bromo-3-(4-nitrophenyl)-1H-pyrazole
[0173] A solution of Intermediate 14 (595 mmol) in DMF (1 L) was treated with N-bromo succinimide (654 mmol). The reaction was stirred for 30 min at room temperature and poured into ice-water (1 L). The product precipitated out of solution and was filtered, washed with water (4×500 mL) and dried to provide Intermediate 19 as an off-white powder (90%). ESMS [M+H]+=269.2.
Intermediate 20
2-[4-bromo-3-(4-nitrophenyl)-1H-pyrazol-1-yl]ethanol
[0174] To a mixture of sodium hydride (60% dispersion in mineral oil, 10 g, 250 mmol) in N,N-dimethylformamide (250 mL) was added a solution of Intermediate 19 (57 g, 210 mmol) in N,N-dimethylformamide (250 mL) via addition funnel over 45 minutes. After stirring for an additional 30 min, 2-bromoethanol (18 mL, 250 mmol) was added dropwise. The solution was stirred at room temperature for 16 h. The reaction was quenched by the addition of saturated NH 4 Cl (100 mL) and EtOAc (300 mL). The organic layer was washed with aqueous 5% lithium chloride solution (2×100 mL) and water (3×100 mL). The organic layer was dried over sodium sulfate, filtered, and concentrated under reduced pressure. The residue was suspended in methylene chloride (200 mL) and the solids were filtered and suspended in 1:1 Hexanes/ethyl acetate (200 mL). After stirring the precipitate for 3 h the solids were filtered and dried to obtain 15 (24 g, 37%) as a tan solid. The filtrates were combined and purified by chromatography (silica, 0-30% ethyl acetate/methylene chloride). The product was obtained as a mixture of regioisomers and was suspended in 1:1 hexanes/ethyl acetate (50 mL) and stirred to 30 min, filtered and dried to obtain Intermediate 20 (6 g, 9%) as a tan solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 8.34-8.31 (m, 2H), 8.16-8.12 (m, 3H), 4.98 (t, J=5.0 Hz, 1H), 4.23 (t, J=5 Hz, 2H), 3.79 (t, J=5 Hz, 2H), 3.32 (s, 3H).
Intermediate 21
2-[3-(4-nitrophenyl)-4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)-1H-pyrazol-1-yl]ethanol
[0175] A mixture of Intermediate 20 (30 g, 96 mmol), bis(pinacolato)diboron (49 g, 190 mmol), and potassium acetate (27 g, 280 mmol) in 1,4-dioxane (1000 mL) was degassed with argon for 30 min followed by the addition of trans-dichloro-bis(triphenylphosphine)-palladium (II) (3.4 g, 4.8 mmol). The reaction mixture was stirred at 100° C. for 16 h. The crude reaction was filtered through diatomaceous earth and the filtrate was concentrated and purified by MPLC (silica, 0-50% ethyl acetate/methylene chloride) to afford a 1:1 mixture of Intermediate 21 and the dehalogenated side product (29 g) as analyzed by LCMS: ESI MS m/z 360 [C 17 H 22 BN 3 O 5 +H] + .
Intermediate 22
2-[4-(2-chloro-4-pyrimidinyl)-3-(4-nitrophenyl)-1H-pyrazol-1-yl]ethanol
[0176] To a solution of Intermediate 21 and the dehalogenated side product (29 g) in ethanol (350 mL) was added 2,4-dichloropyrimidine (24 g, 162 mmol), trans-dichlorobis(triphenylphosphine)palladium (II) (1.82 g, 2.60 mmol) and a solution of sodium carbonate (17 g, 162 mmol) in water (50 mL). The resulting reaction mixture was stirred at 80° C. for 16 h. The reaction was cooled and filtered and the filtrate was concentrated and purified by MPLC (silica, 0-50% ethyl acetate/methylene chloride to elute the dehalogenated side product and then 5% methanol/methylene chloride containing 1% ammonium hydroxide) to give Intermediate 22 (5.4 g, 16% over 2 steps) as an oil: ESI MS m/z 346 [C 15 H 12 ClN 5 O 3 +H] + .
[0000]
Intermediates 25 & 26
[0177] To a stirred solution of Intermediate 23 or 24 (60 mmol) in methylene chloride (200 mL) was added manganese oxide (52 g, 600 mmol). The reaction mixture was stirred at room temperature for 2 days and filtered through diatomaceous. The filter cake was washed with methylene chloride (500 mL) and the filtrate was concentrated under reduced pressure to afford the crude aldehyde. To a solution of the aldehyde (8.7 g, 54 mmol) at −78° C. in tetrahydrofuran (180 mL) was added MeLi (2 M in THF, 80 mmol, 40 mL) dropwise via addition funnel. The resulting solution was stirred under nitrogen, at −78° C., for 4 hours. The reaction mixture was quenched slowly with saturated ammonium chloride solution at −78° C. and warmed to 0° C. The mixture was partitioned between ethyl acetate (500 mL) and water (300 mL). The organic layer was separated, dried over sodium sulfate and concentrated under reduced pressure. The crude oil was purified by chromatography (silica gel, 2:1 hexanes/ethyl acetate) to afford the alcohol intermediate. To a stirred solution of the alcohol (4.0 g, 22 mmol) in methylene chloride (75 mL) was added manganese oxide (26 g, 300 mmol). The reaction mixture was stirred at room temperature for 2 days and then filtered through diatomaceous. The filter cake was washed with methylene chloride (500 mL) and the filtrate was concentrated under reduced pressure and the resulting solid was purified by chromatography (silica gel, 4:1 hexanes/ethyl acetate).
[0178] Intermediate 25 (4.3 g, 35% for 3 steps): 1 H NMR (500 MHz, CDCl 3 ) 8.01-7.99 (m, 1H), 7.91 (s, 1H), 7.89-7.82 (m, 1H), 2.65-2.64 (m, 6H); HPLC >99%, t R =8.05 min;
[0179] Intermediate 26 (1.6 g, 24% for 3 steps): 1 H NMR (500 MHz, CDCl 3 ) 7.90-7.88 (m, 1H), 7.68 (s, 1H), 7.53-7.55 (m, 1H), 4.01 (s, 3H), 2.65 (s, 3H).
Intermediates 27 & 28
[0180] A slurry of Intermediate 25 or 26 (23 mmol) in N,N-dimethylformamide dimethylacetal (56 g, 470 mmol) was stirred at 60° C. for 3 h and concentrated under reduced pressure. The crude residue was dissolved in ethanol (32 mL), cooled to 0° C., and hydrazine monohydrate (5.9 g, 120 mmol) was added dropwise while maintaining the reaction temperature below 10° C. Once the addition was complete the ice bath was removed and the reaction mixture was stirred at room temperature for 1.5 h. The reaction was cooled to 0° C., quenched with water (30 mL), and extracted with ethyl acetate (250 mL). The organic layer was dried over sodium sulfate and concentrated under reduced pressure. The crude residue was purified by chromatography (silica gel, 2:1 hexanes/ethyl acetate).
[0181] Intermediate 27 (2.0 g, 42%) as an oil: 1 H NMR (500 MHz, CDCl 3 ) δ 10.80 (bs, 1H), 8.07-8.06 (m, 1H), 7.79-7.74 (m, 2H), 7.67-7.66 (m, 1H), 6.73-6.72 (m, 1H), 2.67 (s, 3H)
[0182] Intermediate 28 (1.4 g, 78%) as a yellow solid: it was carried crude to next step.
Intermediates 29 & 30
[0183] To a solution of Intermediate 27 or 28 (9.8 mmol) in N,N-dimethylformamide (20 mL) at ° C. was added N-bromo succinimide (2.3 g, 13 mmol). The resulting solution was stirred at room temperature for 14 h. The reaction mixture was quenched with water (100 mL), stirred for 0.5 h, and the resulting precipitate was collected by filtration.
[0184] Intermediate 29: 2.5 g, 89%; ESI MS m/z 282/284 [C 10 H 8 BrN 3 O 2 +H] +
[0185] Intermediate 30: 1.7 g, 89%
[0186] Intermediates 29 & 30 were converted to the corresponding boronates according to the procedure established for Intermediate 17.
[0000]
Intermediate 32
[0187] To a solution of pyrazole 31 (1 equiv.) and the substituted aniline (1.2-1.5 equiv.) in 2-propanol or 1-pentanol (0.25-0.15 M) at 70° C. was added 6 N HCl in 2-propanol (1.2 equiv) and the reaction mixture was heated at 85° C. (2-propanol) or 140° C. (1-pentanol) until the reaction was determined to be complete by LCMS. In certain cases a small quantity of DMSO was added to the reaction if the starting materials were not soluble. The reaction mixture was concentrated under reduced pressure and the residue was dissolved in ethyl acetate and washed with saturated ammonium chloride solution. The organic phase was dried over Na 2 SO 4 , filtered, concentrated and purified by flash chromatography (silica, 0-20% methanol/methylene chloride) to afford Intermediate 32.
[0188] The intermediates 32(a)-32(l) were prepared according the procedure outlined for Intermediate 32:
Intermediate 32(a)
2-{4-[2-[(3-fluorophenyl)amino]-4-pyrimidinyl}-3-(4-nitrophenyl)-1H-pyrazol-1-yl]ethanol
[0189] Yield 86%, ESI MS m/z 421 [C 21 H 17 FN 6 O 3 +H] + .
Intermediate 32(b)
2-[3-(4-nitrophenyl)-4-(2-{[3-(1-pyrrolidinylmethyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-1-yl]ethanol
[0190] Yield 52%, 1 H NMR (400 MHz, MeOD-d 4 ) δ 8.67 (s, 1H), 8.34 (m, 1H), 8.03 (d, J=8.6 Hz, 2H), 7.75 (d, J=8.6 Hz, 2H), 7.53 (m, 1H), 7.35 (m, 1H), 7.28 (m, 1H), 7.17 (m, 2H), 4.41 (t, J=5.3 Hz, 2H), 4.29 (s, 2H), 4.02 (t, J=5.3 Hz, 2H), 3.52 (m, 4H), 3.17 (m, 4H); ESI MS m/z 486 [C 26 H 27 FN 7 O 3 +H] + .
Intermediate 32(c)
2-[4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-3-(4-nitrophenyl)-1H-pyrazol-1-yl]ethanol
[0191] Yield 97%, ESI MS m/z 516 [C 27 H 29 N 7 O 4 +H] + .
Intermediate 32(d)
2-{3-(3-methyl-4-nitrophenyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-1-yl}ethanol
[0192] Yield 66%, ESI MS m/z 530 [C 28 H 31 N 7 O 4 +H] + .
Intermediate 32(e)
2-{3-[3-(methyloxy)-4-nitrophenyl]-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-1-yl}ethanol
[0193] Yield 83%, ESI MS m/z 546 [C 28 H 31 N 7 O 5 +H] + .
Intermediate 32(f)
2-[4-[2-({3-[(4-methyl-1-piperazinyl)methyl]phenyl}amino)-4-pyrimidinyl]-3-(4-nitrophenyl)-1H-pyrazol-1-yl]ethanol
[0194] Yield 55%, ESI MS m/z 515 [C 27 H 30 N 8 O 3 +H] + .
Intermediate 32(g)
2-[4-(2-{[3-(4-methyl-1-piperazinyl)phenyl]amino}-4-pyrimidinyl)-3-(4-nitrophenyl)-1H-pyrazol-1-yl]ethanol
[0195] Yield 65%, ESI MS m/z 501 [C 26 H 28 N 8 O 3 +H] + .
Intermediate 32(h)
2-{4-[3-({4-[1-methyl-3-(4-nitrophenyl)-1H-pyrazol-4-yl]-2-pyrimidinyl}amino)phenyl]-1-piperazinyl}ethanol
[0196] Yield 52%, 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.28 (s, 1H), 8.40-8.37 (m, 2H), 8.21-8.14 (m, 2H), 7.86-7.81 (m, 2H), 7.17 (s, 1H), 6.98-6.95 (m, 1H), 6.84 (t, J=8.08 Hz, 1H), 6.78 (d, J=5.31 Hz, 1H), 6.45 (d, J=2.27 Hz, 1H), 4.46-4.443 (m, 1H), 3.99 (s, 3H), 2.55-2.52 (s, 2H), 3.18-3.16 (m, 2H), 3.09-2.91 (m, 4H), 2.50-2.33 (m, 4H). ESI MS m/z 501 [C 26 H 28 N 8 O 3 +H] + ; analytical HPLC t R =2.15 min.
Intermediate 32(i)
4-[1-methyl-3-(4-nitrophenyl)-1H-pyrazol-4-yl]-N-[3-(1-pyrrolidinylmethyl)phenyl]-2-pyrimidinamine
[0197] Yield 71%, ESI MS m/z 456 [C 25 H 25 N 7 O 2 +H] + .
Intermediate 32(j)
2-(4-{[3-({4-[1-methyl-3-(4-nitrophenyl)-1H-pyrazol-4-yl]-2-pyrimidinyl}amino)phenyl]methyl}-1-piperazinyl)ethanol
[0198] Yield 46%, ESI MS m/z 515 [C 27 H 30 N 8 O 3 +H] + .
Intermediate 32(k)
4-[1-methyl-3-(4-nitrophenyl)-1H-pyrazol-4-yl]-N-[3-(4-methyl-1-piperazinyl)phenyl]-2-pyrimidinamine
[0199] Yield 83%, 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.27 (s, 1H), 8.38 (d, J=5.2 Hz, 1H), 8.37 (s, 1H), 8.18 (d, J=9.2 Hz, 2H), 7.83 (d, J=9.2 Hz, 2H), 7.17 (s, 1H), 6.95 (d, J=8.3 Hz, 1H), 6.82 (t, J=8.3 Hz, 1H), 6.78 (d, J=5.2 Hz, 1H), 6.45 (d, J=8.3 Hz, 1H), 3.99 (s, 3H), 3.00 (m, 4H), 2.41 (m, 4H), 2.21 (s, 3H); ESI MS m/z 471 [C 25 H 26 N 8 O 2 +H] + .
Intermediate 32(l)
4-[1-methyl-3-(4-nitrophenyl)-1H-pyrazol-4-yl]-N-{3-[2-(4-morpholinyl)ethyl]phenyl}-2-pyrimidinamine
[0200] Yield 74%, ESI MS m/z 486 [C 26 H 27 N 7 O 3 +H] + .
[0000]
Intermediate 33
[0201] Intermediate 33 may be obtained from Intermediate 32 by reduction of the nitro group.
Method A
[0202] To a solution of Intermediate 32 (1 equiv) in 1:1 6N HCl/ethanol (25 mL/g of substrate) was added tin (5 equiv) and the mixture was heated at 70° C. for 1 h. The reaction mixture was filtered to remove the solids and the filtrate was concentrated. The crude residue was suspended in ethyl acetate (500 mL/g of substrate) and 2 N NaOH (300 mL/g of substrate) and stirred vigorously for 2 h. The reaction mixture was filtered through diatomaceous earth and the biphasic filtrate was separated. The aqueous phase was extracted with ethyl acetate and the combined organic phases were washed with water and brine, dried over Na 2 SO 4 , filtrated and concentrated under reduced pressure to afford Intermediate 33.
Method B
[0203] To a solution of Intermediate 32 (2.0 mmol) and copper (I) chloride (3.5 g, 35 mmol) in anhydrous tetrahydrofuran (10 mL) and anhydrous methanol (10 mL) was added KBH 4 (2.3 g, 41 mmol) portion wise. The mixture evolved gas and after 15 min was heated at 70° C. under a nitrogen atmosphere for 18 h. The mixture was cooled, diluted with 1:1 methanol/water (200 mL each) and filtered through a pad of diatomaceous earth. The filtrate was concentrated under reduced pressure and purified via chromatography (silica, 0-20% CMA/methylene chloride) to obtain Intermediate 33.
[0204] The intermediates 33(a)-33(l) were prepared according the procedure outlined for Intermediate 33:
Intermediate 33(a)
2-[4-{2-[(3-fluorophenyl)amino]-4-pyrimidinyl}-3-(4-aminophenyl)-1H-pyrazol-1-yl]ethanol
[0205] Yield 99%, ESI MS m/z 391 [C 21 H 19 FN 6 O+H] + .
Intermediate 33(b)
2-[3-(4-aminophenyl)-4-(2-{[3-(1-pyrrolidinylmethyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-1-yl]ethanol
[0206] Yield 99%, 1 H NMR (400 MHz, MeOD-d 4 ) δ 8.22 (s, 1H), 8.14 (d, J=5.2 Hz, 1H), 7.62 (s, 1H), 7.57 (d, J=7.6 Hz, 1H), 7.25 (d, J=8.6 Hz, 2H), 7.22 (t, J=7.6 Hz, 1H), 6.96 (d, J=7.6 Hz, 1H), 6.75 (d, J=8.6 Hz, 2H), 6.61 (d, J=5.2 Hz, 1H), 4.24 (t, J=5.3 Hz, 2H), 3.95 (t, J=5.3 Hz, 2H), 3.64 (s, 2H), 2.62 (m, 4H), 1.81 (m, 4H); ESI MS m/z 456 [C 26 H 29 FN 7 O+H] + .
Intermediate 33(c)
2-[4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-3-(4-aminophenyl)-1H-pyrazol-1-yl]ethanol
[0207] Yield 97%, ESI MS m/z 486 [C 27 H 31 N 7 O 2 +H] + .
Intermediate 33(d)
2-{3-(3-methyl-4-aminophenyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-1-yl}ethanol
[0208] Yield 99%, ESI MS m/z 500 [C 28 H 33 N 7 O 2 +H] + .
Intermediate 33(e)
2-{3-[3-(methyloxy)-4-aminophenyl]-4-[2-({3-[2-(4-morpholinyl ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-1-yl}ethanol
[0209] Yield 68%, ESI MS m/z 516 [C 28 H 33 N 7 O 3 +H] + .
Intermediate 33(f)
2-[4-[2-({3-[(4-methyl-1-piperazinyl)methyl]phenyl}amino)-4-pyrimidinyl]-3-(4-aminophenyl)-1H-pyrazol-1-yl]ethanol
[0210] Yield 71%, ESI MS m/z 485 [C 27 H 32 N 8 O+H] + .
Intermediate 33(g)
2-[4-(2-{[3-(4-methyl-1-piperazinyl)phenyl]amino}-4-pyrimidinyl)-3-(4-aminophenyl)-1H-pyrazol-1-yl]ethanol
[0211] Yield 82%, ESI MS m/z 471 [C 26 H 30 N 8 O+H] + .
Intermediate 33(h)
2-{4-[3-({4-[1-methyl-3-(4-aminophenyl)-1H-pyrazol-4-yl]-2-pyrimidinyl}amino)phenyl]-1-piperazinyl}ethanol
[0212] Yield 75%, ESI MS m/z 471 [C 26 H 30 N 8 O+H] + ; analytical HPLC t R =1.61 min.
Intermediate 33(i)
4-[1-methyl-3-(4-aminophenyl)-1H-pyrazol-4-yl]-N-[3-(1-pyrrolidinylmethyl)phenyl]-2-pyrimidinamine
[0213] Yield 67%, ESI MS m/z 426 [C 25 H 27 N 7 +H] + .
Intermediate 33(j)
2-(4-{[3-({4-[1-methyl-3-(4-aminophenyl)-1H-pyrazol-4-yl]-2-pyrimidinyl}amino)phenyl]methyl}-1-piperazinyl)ethanol
[0214] Yield 92%, ESI MS m/z 485 [C 27 H 33 N 8 O 3 +H] + .
Intermediate 33(k)
4-[1-methyl-3-(4-aminophenyl)-1H-pyrazol-4-yl]-N-[3-(4-methyl-1-piperazinyl)phenyl]-2-pyrimidinamine
[0215] Yield 52%, 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.30 (s, 1H), 8.27 (d, J=5.3 Hz, 1H), 8.22 (s, 1H), 7.54 (d, J=8.6 Hz, 2H), 7.42 (s, 1H), 7.36 (d, J=8.6 Hz, 1H), 7.18 (d, J=8.1 Hz, 1H), 7.04 (t, J=8.1 Hz, 1H), 6.54 (d, J=5.3 Hz, 1H), 6.45 (d, J=8.1 Hz, 1H), 3.94 (s, 3H), 3.08 (m, 4H), 2.45 (m, 4H), 2.22 (s, 3H); ESI MS m/z 441 [C 25 H 28 N 8 +H] + .
Intermediate 33(l)
4-[1-methyl-3-(4-nitrophenyl)-1H-pyrazol-4-yl]-N-{3-[2-(4-morpholinyl)ethyl]phenyl}-2-pyrimidinamine
[0216] Yield 84%, ESI MS m/z 456 [C 26 H 29 N 7 O+H] + .
General Synthesis of Urea Targets From Intermediate 33.
[0217] Acylation of Intermediate 33 using the appropriate method afforded the desired target compound (I):
[0000]
Method A
[0218] To a solution of phosgene (1.7 M in toluene, 0.50 mL, 0.86 mmol) in THF (5 mL) at 0° C. was added Intermediate 33 (0.66 mmol). The resulting suspension was warmed to room temperature and stirred for 15 min. Diethyl amine (0.34 mL, 3.3 mmol) was added and the resulting mixture was stirred for 16 h. The reaction was quenched by the addition of saturated NH 4 Cl (15 mL) and diluted with EtOAc (50 mL). The organics were dried over Na 2 SO 4 , concentrated and purified by MPLC (silica, 0-15% methanol/methylene chloride). The crude product was further purified by semi-preparatory HPLC (reverse phase silica, 15-90% methanol/NH 4 OAc buffer) to afford the pure desired product which was dissolved in 5-6N HCl in IPA (2 mL) followed by trituration with diethyl ether (30 mL). The solids were filtered and lyophilized to afford desired product (I), where R 1 ═NR 3 R 4 .
Method B
[0219] 4-nitrophenylchloroformate (112 mg, 0.54 mmol) was added portion wise to a solution of Intermediate 33 (2.24 mmol) in methylene chloride (1.5 mL) and pyridine (1.5 mL) at 0° C. and stirred for 1 h. The formation of the carbamate intermediate was monitored by LCMS followed by the addition of pyrrolidine (0.5 mL). The reaction mixture was allowed to warm to rt and stirred for 18 h. The resulting yellow solution was poured into saturated sodium bicarbonate solution (50 mL) and extracted with methylene chloride (3×50 mL). The combined organic phases were washed with water (25 mL) and brine (25 mL), dried over Na 2 SO 4 , filtrated, concentrated and purified by MPLC to afford product (I), where R 1 ═NR 3 R 4 .
Method C
[0220] To a solution of Intermediate 33 (0.51 mmol) in tetrahydrofuran (7.0 mL) was added dimethylcarbamyl chloride (2.2 g, 20 mmol). The reaction mixture was stirred at 45° C. for 3 days and concentrated under reduced pressure. The crude residue was purified by chromatography (silica gel, 94.5:5.0:0.5 methylene chloride/methanol/concentrated ammonium hydroxide) to afford the product (0.15 g) which was dissolved in iPrOH (3 mL) followed by dropwise addition of 5-6 N hydrochloric acid in iPrOH (0.10 mL). The mixture was stirred at room temperature for 15 min and concentrated to provide product (I), where R 1 ═NR 3 R 4 .
Method D
[0221] (This method should be used for compounds that containing unprotected hydroxy groups in R4, R5, R5 or R6.)
[0222] Step 1: To a solution of Intermediate 33 (0.45 mmol) and imidazole (90 mg, 1.3 mmol) in N,N-dimethylformamide (3 mL) at 0° C. was added tert-butyl dimethylsilylchloride (0.15 g, 0.99 mmol) in one portion. The reaction mixture was stirred at 0° C. for 15 min and room temperature for 20 h. The reaction mixture was concentrated under reduced pressure and the residue was partitioned between ethyl acetate (20 mL) and water (10 mL). The organic layer was separated, dried over sodium sulfate, and concentrated under reduced pressure to provide the protected intermediate which was used crude in the next step.
[0223] Step 2: To a solution of the intermediate from step 1 (0.35 g, 0.59 mmol) in pyridine (6.0 mL) at 0° C. was added a 16% v/v solution of methyl isocyante in tetrahydrofuran (37 mg, 0.65 mmol). The resulting mixture was stirred, under nitrogen and at room temperature, for 18 h. The reaction mixture was concentrated under reduced pressure and the crude residue purified by chromatography (silica gel, 94.5:5.0:0.5 methylene chloride/methanol/concentrated ammonium hydroxide) to provide the methyl urea intermediate. To a solution of the methyl urea intermediate (0.21 g, 0.32 mmol) in ethanol (3 mL) was added 6N hydrochloric acid (4 mL). The resulting mixture was stirred at room temperature for 1.5 h and washed with diethyl ether (20 mL). The aqueous layer was separated, concentrated under reduced pressure, and the crude residue was purified by chromatography (silica gel, 94.5:5.0:0.5 methylene chloride/methanol/concentrated ammonium hydroxide) to provide the deprotected intermediate. The deprotected intermediate (0.28 mmol) was dissolved in a mixture of methanol (2 mL) and 2-PrOH (1 mL) and a 1M solution of hydrochloric acid in diethyl ether (0.55 mL) was added dropwise. The resulting mixture was stirred for 15 minutes and sonicated before concentrating under reduced pressure to afford product (I), where R 1 ═NR 3 R 4 .
Example 54
N-{4-[4-{2-[(3-fluorophenyl)amino]-4-pyrimidinyl}-1-(2-hydroxyethyl)-1H-pyrazol-3-yl]phenyl}-1-pyrrolidinecarboxamide
[0224] Method B, 33% as a white solid: mp 185-186° C.; 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.72 (s, 1H), 8.33 (d, J=5.2 Hz, 1H), 8.25 (m, 1H), 8.18 (m, 1H), 7.68-65 (m, 1H), 7.57-56 (m, 2H), 7.46-44 (m, 1H), 7.36-35 (m 2H), 7.21-19 (m, 1H), 6.70-66 (m, 1H), 6.64-63 (m, 1H), 5.01-4.99 (m, 1H), 4.24-22 (m, 2H), 3.82-3.79 (m, 2H), 3.37-36 (m, 4H), 1.85 (m, 4H); ESI MS m/z 488 [C 26 H 26 FN 7 O 2 +H] + ; HPLC t R =12.46 min, 98.3% (AUC).
Example 55
N-cyclopropyl-N′-(4-{1-methyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)urea
[0225] Method A, 48% as an off-white solid: mp 143-145° C.; 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.36 (s, 1H), 8.38 (s, 1H), 8.28 (d, J=5.2 Hz, 1H), 8.21 (s, 1H), 7.55 (s, 1H), 7.50 (d, J=8.0 Hz, 1H), 7.43 (d, J=8.7 Hz, 2H), 7.36 (d, J=8.7 Hz, 2H), 7.08 (t, J=7.8 Hz, 1H), 6.76 (d, J=7.5 Hz, 1H), 6.56 (d, J=5.1 Hz, 1H), 6.40 (d, J=2.6 Hz, 1H), 3.92 (s, 3H), 3.57 (s, 4H), 2.65 (t, J=8.0 Hz, 2H), 2.56-2.52 (m, 3H), 2.49-2.35 (m, 4H), 0.65-0.61 (m, 2H), 0.42-0.38 (m, 2H); ESI MS m/z 539 [C 30 H 34 N 8 O 2 +H] + ; HPLC 98.6%, t R =9.3 min.
Example 56
N-(4-{1-methyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}phenyl)-1-pyrrolidinecarboxamide
[0226] Method A, off-white solid, mp=228-30° C., 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.37 (s, 1H), 8.36 (m, 2H), 8.17 (d, 1H), 8.08 (s, 1H), 7.73 (d, 2H), 7.65 (s, 1H), 7.47 (d, 1H), 7.31 (d, 2H), 7.13 (t, 1H), 6.78 (d, 1H), 6.25 (d, 1H), 3.68 (s, 3H), 3.58 (m, 4H), 3.40 (m, 4H), 2.70 (m, 2H), 2.53 (br, 1H), 2.44 (br, 4H), 1.87 (br, 4H). ESI MS m/z 553 [M+H] + .
Example 57
N-(4-{1-(2-hydroxyethyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)-1-pyrrolidinecarboxamide
[0227] Method A, 22% as an off-white solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.39 (s, 1H), 8.38 (bs, 1H), 8.28-8.27 (m, 1H), 8.23 (s, 1H), 8.19 (s, 1H), 7.59-7.56 (m, 3H), 7.51-7.49 (m, 1H), 7.37-7.35 (m, 2H), 7.09 (t, J=7.8 Hz, 1H), 6.77-6.76 (m, 1H), 6.56-6.55 (m, 1H), 4.23-4.21 (m, 2H), 3.82-3.80 (m, 2H), 3.58-3.56 (m, 4H), 3.39-3.36 (m, 6H), 2.67-2.63 (m, 2H), 2.50-2.47 (m, 2H), 2.41-2.36 (m, 4H), 1.87-1.84 (m, 4H); ESI MS m/z 583 [C 32 H 38 N 8 O 3 +H] + ; HPLC 98.9% (AUC), t R =9.33 min.
Example 58
N-cyclopropyl-N′-(4-{1-(2-hydroxyethyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}-2-methylphenyl)urea
[0228] Method A, 22% as a white solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.41 (s, 1H), 8.27-8.26 (m, 1H), 8.24 (s, 1H), 7.92-7.91 (m, 1H), 7.60 (s, 1H), 7.56 (m, 1H), 7.50-7.49 (m, 1H), 7.31-7.30 (m, 1H), 7.23-7.21 (m, 1H), 7.09-7.06 (m, 1H), 6.82-6.81 (m, 1H), 6.77-6.76 (m, 1H), 6.57-6.56 (m, 1H), 5.05-5.03 (m, 1H), 4.23-4.21 (m, 2H), 3.82-3.79 (m, 2H), 3.58-3.56 (m, 4H), 2.67-2.60 (m, 2H), 2.58-2.53 (m, 1H), 2.48-2.46 (m, 2H), 2.42-2.39 (m, 4H), 2.16 (s, 3H), 0.66-0.61 (m, 2H), 0.45-0.40 (m, 2H); ESI MS m/z 582 [C 32 H 38 N 8 O 3 +H] + ; HPLC >99% (AUC), t R =9.03 min.
Example 59
N,N-diethyl-N′-(4-{4-[2-({3-[4-(2-hydroxyethyl)-1-piperazinyl]phenyl}amino)-4-pyrimidinyl]-1-methyl-1H-pyrazol-3-yl}phenyl)urea
[0229] Method A, 34% as a yellow solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 10.37 (bs, 1H), 9.62 (bs, 1H), 8.31-8.26 (m, 3H), 7.56-7.54 (m, 2H), 7.44 (s, 1H), 7.38-7.36 (m, 2H), 7.19-7.17 (m, 1H), 7.13-7.10 (m, 1H), 6.63-6.60 (M, 2H), 3.95 (s, 3H), 3.83-3.81 (m, 2H), 3.70-3.68 (m, 2H), 3.61-3.59 (m, 2H), 3.38-3.33 (m, 4H), 3.26-3.10 (m, 6H), 1.09 (t, J=7.0 Hz, 6H); ESI MS m/z 570 [C 31 H 39 N 9 O 2 +H] + ; HPLC 95.5% (AUC), t R =9.86 min.
Example 60
N,N-diethyl-N′-{4-[1-methyl-4-(2-{[3-(4-methyl-1-piperazinyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}urea
[0230] Method A, 50% as a yellow solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 10.87 (bs, 1H), 9.66 (bs, 1H), 8.30-8.27 (m, 3H), 7.56-7.54 (m, 2H), 7.43 (s, 1H), 7.38-7.36 (m, 2H), 7.19-7.10 (m, 2H), 6.64-6.61 (m, 2H), 3.95-3.91 (m, 3H), 3.71-3.68 (m, 2H), 3.49-3.47 (m, 2H), 3.36 (q, J=14.0, 7.0 Hz, 4H), 3.17-3.05 (m, 4H), 2.81-2.78 (m, 3H), 1.09 (t, J=7.0 Hz, 6H); ESI MS m/z 540 [C 30 H 37 N 9 O+H] + ; HPLC 98.4% (AUC), t R =9.83 min.
Example 61
N-ethyl-N′-(4-{1-methyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)urea
[0231] Method A, light brown solid, mp=139-41 C, 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.35 (s, 1H), 8.50 (s, 1H), 8.25 (d, 1H), 8.20 (s, 1H), 7.55 (s, 1H), 7.50 (d, 1H), 7.40 (d, 2H), 7.35 (d, 2H), 7.05 (t, 1H), 6.85 (d, 1H), 6.55 (d, 1H), 6.10 (t, 1H), 3.95 (s, 3H), 3.55 (br, 4H), 3.10 (m, 2H), 2.65 (m, 2H), 2.40 (m, 4H), 1.03 (t, 3H). ESI MS m/z 527 [M+H] + .
Example 62
N,N-diethyl-N′-[4-(4-{2-[(3-{[4-(2-hydroxyethyl)-1-piperazinyl]methyl}phenyl)amino]-4-pyrimidinyl}-1-methyl-1H-pyrazol-3-yl)phenyl]urea
[0232] Method A, 39% as a yellow solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 11.14 (bs, 1H), 9.74 (bs, 1H), 8.32-8.28 (m, 3H), 7.82-7.81 (m, 1H), 7.67-7.66 (m, 1H), 7.56-7.54 (m, 2H), 7.37-7.35 (m, 2H), 7.31-7.28 (m, 1H), 7.26-7.22 (m, 1H), 6.65-6.64 (m, 1H), 4.26 (bs, 2H), 3.95 (s, 3H), 3.81-3.76 (m, 4H), 3.54-3.50 (m, 4H), 3.38-3.33 (m, 6H), 3.21-3.16 (m, 2H), 1.11-1.08 (m, 6H); ESI MS m/z 584 [C 32 H 41 N 9 O 2 +H] + ; HPLC 96.7% (AUC), t R =9.10 min.
Example 63
N-(4-{1-methyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)-1-pyrrolidinecarboxamide
[0233] Method A, 70% as a yellow solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 10.9 (bs, 1H), 9.61 (s, 1H), 8.30-8.27 (m, 2H), 8.23 (s, 1H), 7.64-7.63 (m, 1H), 7.57-7.55 (m, 2H), 7.51-7.50 (m, 1H), 7.38-7.36 (m, 2H), 7.19 (t, J=7.8 Hz, 1H), 6.84-6.82 (m, 1H), 6.62-6.61 (m, 1H), 4.00-3.95 (m, 5H), 3.81-3.77 (m, 2H), 3.50-3.48 (m, 2H), 3.39-3.36 (m, 4H), 3.31-3.23 (m, 2H), 3.14-3.06 (m, 2H), 3.00-2.96 (m, 2H), 1.87-1.84 (m, 4H); ESI MS m/z 553 [C 31 H 36 N 8 O 2 +H] + ; HPLC 99.0% (AUC), t R =9.43 min.
Example 64
N-ethyl-N′-(4-{1-methyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)urea
[0234] Method B, 22% as a light brown solid: mp 139-141° C.; 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.37 (s, 1H), 8.50 (s, 1H), 8.28 (d, J=5.1 Hz, 1H), 8.21 (s, 1H), 7.55 (s, 1H), 7.50 (d, J=8.1 Hz, 1H), 7.43-7.41 (m, 2H), 7.36-7.34 (m, 2H), 7.09 (t, J=7.7 Hz, 1H), 6.76 (d, J=7.6 Hz, 1H), 6.57 (d, J=5.2 Hz, 1H), 6.11-6.10 (m, 1H), 3.93 (s, 3H), 3.57 (s, 4H), 3.12-3.10 (m, 2H), 2.66-2.64 (m, 2H), 2.53-2.49 (m, 2H), 2.43-2.41 (m, 4H), 1.07-1.04 (m, 3H); ESI MS m/z 527 [C 29 H 34 N 8 O 2 +H] + ; HPLC 95.6%, t R =9.0 min.
Example 65
N,N-dimethyl-N′-(4-{1-methyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)urea
[0235] Method B, 52% as a white powder: mp 132-134° C.; 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.39 (s, 1H), 8.37 (s, 1H), 8.28 (d, J=5.2 Hz, 1H), 8.21 (s, 1H), 7.56-7.51 (m, 4H), 7.37-7.35 (m, 4H), 7.10-7.08 (m, 1H), 6.77 (d, J=7.6 Hz, 1H), 6.56 (d, J=5.2 Hz, 1H), 3.93 (s, 3H), 3.57 (t, J=4.6 Hz, 4H), 2.93 (s, 6H), 2.70-2.61 (m, 2H), 2.51-2.49 (m, 2H), 2.45-2.37 (m, 4H); ESI MS m/z 527 [C 29 H 34 N 8 O 2 +H] + ; HPLC 98.6%, t R =9.0 min.
Example 66
N-ethyl-N′-(4-{1-(2-hydroxyethyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}-2-methylphenyl)urea
[0236] Method A, 26% as a white solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.41 (s, 1H), 8.27-8.26 (m, 1H), 8.24 (s, 1H), 7.93-7.91 (m, 1H), 7.64-7.60 (m, 2H), 7.50-7.48 (m, 1H), 7.30 (s, 1H), 7.22-7.20 (m, 1H), 7.09-7.06 (m, 1H), 6.77-6.76 (m, 1H), 6.59-6.56 (m, 2H), 5.05-5.03 (m, 1H), 4.23-4.21 (m, 2H), 3.82-3.79 (m, 2H), 3.58-3.56 (m, 4H), 3.14-3.09 (m, 2H), 2.66-2.63 (m, 2H), 2.41-2.36 (m, 4H), 2.16 (s, 3H), 1.07 (t, J=7.1 Hz, 3H); ESI MS m/z 571 [C 31 H 38 N 8 O 3 +H] + ; HPLC >99% (AUC), t R =6.02 min.
Example 67
N,N-diethyl-N′-(4-{1-(2-hydroxyethyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)urea
[0237] Method A, 38% as a white solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.39 (s, 1H), 8.29-8.27 (m, 1H), 8.24 (s, 2H), 7.59 (s, 1H), 7.55-7.54 (m, 2H), 7.51-7.49 (m, 1H), 7.38-7.36 (m, 2H), 7.09 (t, J=7.8 Hz, 1H), 6.77-6.75 (m, 1H), 6.58-6.57 (m, 1H), 4.24-4.22 (m, 2H), 3.82-3.80 (m, 2H), 3.58-3.56 (m, 4H), 3.37-3.33 (m, 5H), 2.67-2.64 (m, 2H), 2.50-2.47 (m, 2H), 2.41-2.36 (m, 4H), 1.09 (t, J=7.0 Hz, 6H); ESI MS m/z 585 [C 32 H 40 N 8 O 3 +H] + ; HPLC >99% (AUC), t R =9.70 min.
Example 68
N,N-diethyl-N′-{4-[1-(2-hydroxyethyl)-4-(2-{[3-(4-methyl-1-piperazinyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}urea
[0238] Method A, 22% as yellow solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.83 (s, 1H), 8.39-8.22 (m, 3H), 7.55 (d, J=7.0 Hz, 2H), 7.42-7.35 (m, 3H), 7.13 (d, J=8.0 Hz, 2H), 6.54-6.51 (m, 2H), 4.27-4.29 (m, 2H), 3.82-3.80 (m, 2H), 3.72-3.70 (m, 2H), 3.49-3.47 (m, 2H), 3.37 (q, J=7.5 Hz, 4H), 3.10-3.08 (m, 4H), 2.81-2.79 (bs, 3H), 1.09 (t, J=7.0 Hz, 6H); ESI MS m/z 570 [C 31 H 39 N 9 O 2 +H] + ; HPLC 95.9%, t R =9.4 min.
Example 69
N,N-diethyl-N′-(4-{1-(2-hydroxyethyl)-4-[2-({3-[(4-methyl-1-piperazinyl)methyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)urea
[0239] Method A, 33% as yellow solid: 1 H NMR (500 MHz, DMSO-d 6 ) 9.92 (s, 1H), 8.39 (s, 1H), 8.3-8.29 (m, 2H), 7.89 (s, 1H), 7.63 (d, J=7.5 Hz, 1H), 7.57 (d, J=8.5 Hz, 2H), 7.38 (d, J=8.5 Hz, 2H), 7.32-7.29 (m, 2H), 6.69 (t, J=5.5 Hz, 1H), 4.30 (m, 2H), 4.26 (t, J=5.5 Hz, 2H), 3.82 (t, J=5.0 Hz, 2H), 3.65-3.46 (m, 8H), 3.37 (q, J=7.5 Hz, 4H), 2.80 (bs, 3H), 1.10 (t, J=7.0 Hz, 6H); ESI MS m/z 584 [C 32 H 41 N 9 O 2 +H] + ; HPLC 97.2%, t R =8.9 min.
Example 70
N-cyclopropyl-N′-[4-{1-(2-hydroxyethyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}-2-(methyloxy)phenyl]urea
[0240] Method A, 28% as yellow solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.42 (s, 1H), 8.29 (d, J=5.5 Hz, 1H), 8.25 (s, 1H), 8.17 (d, J=8.5 Hz, 1H), (s, 1H), 7.60 (s, 1H), 7.49 (d, J=8.5 Hz, 1H), 7.08-7.02 (m, 4H), 6.76 (d, J=7.5 Hz, 1H), 6.62 (d, J=5.5 Hz, 1H), 5.04 (t, J=5.0 Hz, 1H), 4.23 (t, J=5.0 Hz, 2H), 3.82-3.80 (m, 2H), 3.76 (s, 3H), 3.57 (t, J=4.5 Hz, 4H), 2.69-2.63 (m, 2H), 2.56-2.54 (m, 1H), 2.47-2.46 (m, 2H), 2.41-2.39 (m, 4H), 0.65-0.62 (m, 2H), 0.38 (m, 2H); ESI MS m/z 599 [C 32 H 38 N 8 O 4 +H] + ; HPLC 97.5%, t R =9.8 min.
Example 71
N-cyclopropyl-N′-(4-{1-(2-hydroxyethyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}phenyl)urea
[0241] Method A, 21% as yellow solid: 1 H NMR (300 MHz, DMSO-d 6 ) 9.42 (s, 1H), 8.42 (s, 1H), 8.29-8.24 (m, 2H), 7.58-7.35 (m, 6H), 7.09 (t, J=6.0 Hz, 1H), 6.78 (d, J=9.0 Hz, 1H), 6.57 (d, J=6.0 Hz, 1H), 6.43-6.41 (m, 1H), 5.05 (m, 1H), 4.24-4.19 (m, 2H), 3.82-3.79 (m, 2H), 3.59-3.57 (m, 4H), 2.68-2.42 (m, 9H), 0.67-0.62 (m, 2H), 0.42-0.38 (m, 2H); ESI MS m/z 569 [C 31 H 36 N 8 O 3 +H] + ; HPLC >99%, t R =9.0 min.
Example 72
N-methyl-N′-{4-[1-methyl-4-(2-{[3-(1-pyrrolidinylmethyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}urea
[0242] Method A, 64% as yellow solid: mp 175-179° C.; 1 H NMR (500 MHz, DMSO-d 6 ) δ 10.65 (s, 1H), 9.81 (s, 1H), 8.91 (s, 1H), 8.34 (t, J=5.3 Hz, 2H), 7.79 (s, 1H), 7.60 (d, J=8.1 Hz, 1H), 7.42 (d, J=8.6 Hz, 2H), 7.36 (d, J=8.7 Hz, 2H), 7.27 (t, J=7.7 Hz, 1H), 7.20 (d, J=7.6 Hz, 1H), 6.69 (d, J=5.4 Hz, 1H), 4.22 (d, J=5.7 Hz, 2H), 3.94 (s, 3H), 3.36-3.34 (m, 2H), 3.05-3.01 (m, 2H), 2.65 (s, 3H), 2.04-1.97 (m, 2H), 1.88-1.86 (m, 2H); ESI MS m/z 483 [C 27 H 30 N 8 O+H] + ; HPLC >99%, t R =8.9 min.
Example 73
N-[4-(4-{2-[(3-{[4-(2-hydroxyethyl)-1-piperazinyl]methyl}phenyl)amino]-4-pyrimidinyl}-1-methyl-1H-pyrazol-3-yl)phenyl]-N′-methylurea
[0243] Method A, 48% for 3 steps as a yellow solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.50-10.50 (m, 1H), 9.72 (bs, 1H), 8.84 (s, 1H), 8.33-8.31 (m, 2H), 7.79 (s, 1H), 7.66-7.64 (m, 1H), 7.43-7.42 (m, 2H), 7.35-7.34 (m, 2H), 7.29-7.26 (m, 1H), 7.21-7.19 (m, 1H), 6.66-6.65 (m, 1H), 6.20 (bs, 1 h), 3.94 (s, 3H), 3.75-3.22 (m, 15H), 2.70 (s, 3H), ESI MS m/z 542 [C 29 H 35 N 9 O 2 +H] + ; HPLC 97.9% (AUC), t R =8.38 min.
Example 74
N-(4-{4-[2-({3-[4-(2-hydroxyethyl)-1-piperazinyl]phenyl}amino)-4-pyrimidinyl]-1-methyl-1H-pyrazol-3-yl}phenyl)-1-pyrrolidinecarboxamide
[0244] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 9.97 (s, 1H), 9.41 (s, 1H), 8.29 (d, J=5.05 Hz, 1H), 8.24-8.23 (m, 1H), 7.56 (d, J=8.59 Hz, 2H), 7.53-7.50 (m, 1H), 7.37 (d, J=8.59 Hz, 2H), 7.24-7.21 (m, 1H), 7.10 (t, J=8.08 Hz, 1H), 6.62-6.54 (m, 1H), 6.57 (d, J=5.31 Hz, 1H), 5.41-5.40 (m, 1H), 3.95 (s, 3H), 3.83-3.78 (m, 2H), 3.73-3.66 (m, 2H), 3.64-3.58 (m, 2H), 3.43-3.34 (m, 4H), 3.28-3.16 (m, 4H), 3.09-3.05 (m, 2H), 1.91-1.84 (m, 4H); ESI MS (m/z) 568: LCMS retention time t R =1.44 min: analytical HPLC t R =2.03 min.
Example 75
N-{4-[1-methyl-4-(2-{[3-(4-methyl-1-piperazinyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}-1-pyrrolidinecarboxamide
[0245] 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 10.44 (s, 1H) 9.52 (s, 1H) 8.30 (d, J=5.31 Hz, 1H), 8.28-8.23 (m, 1H), 7.57 (d, J=8.84 Hz, 2H), 7.47 (s, 1H), 7.37 (d, J=8.59 Hz, 2H), 7.22-7.18 (m, 1H), 7.11 (t, J=8.08 Hz, 1H), 6.63-6.59 (m, 1H), 6.59 (d, J=5.31 Hz, 1H), 3.95 (s, 3H), 3.72 (d, J=1.01 Hz, 2H), 3.54-3.48 (m, 2H), 3.40-3.36 (m, 4H), 3.21-3.10 (m, 2H), 3.05-2.98 (m, 2H), 2.83 (d, J=4.55 Hz, 3H), 1.88-1.83 (m, 4H); ESI MS (m/z) 538: LCMS retention time t R =1.47 min: analytical HPLC t R =2.06 min.
Example 76
(4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-3-{4-[(1-pyrrolidinylcarbonyl)amino]phenyl}-1H-pyrazol-1-yl)acetic acid
[0246] 1 H NMR (400 MHz, acetone-d 6 ) δ ppm 11.48 (s, 1H), 8.60 (s, 1H), 8.39 (s, 2H), 7.93 (s, 1H), 7.77 (s, 1H), 7.60 (s, 4H), 7.32 (s, 2H), 7.02 (d, J=1.77 Hz, 1H), 5.19 (s, 2H), 4.12 (s, 4H), 3.75 (m, 2H), 3.44-3.52 (m, 4H), 3.30 (m, 2H), 3.00 (d, J=10.11 Hz, 2H), 1.96 (m, 4H); MS (ES) m/e 598 [M+H] + .
Example 77
{3-(4-{[(ethylamino)carbonyl]amino}phenyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-1-yl}acetic acid
[0247] 1 H NMR (400 MHz, acetone-d 6 ) δ ppm 10.79 (s, 2H), 8.46-8.57 (m, 1H), 8.31 (s, 1H), 7.76 (s, 1H), 7.67 (d, J=8.34 Hz, 1H), 7.45-7.56 (m, 3H), 7.39 (d, J=7.83 Hz, 1H), 7.22-7.33 (m, 1H), 7.00 (d, J=7.33 Hz, 1H), 6.91 (d, J=5.56 Hz, 1H), 5.15 (s, 2H), 4.04 (d, J=6.32 Hz, 4H), 3.86 (s, 2H), 3.70 (s, 2H), 3.37-3.46 (m, 2H), 3.31 (d, J=3.28 Hz, 2H), 3.25 (q, J=7.24 Hz, 4H), 3.09 (d, J=8.34 Hz, 2H), 3.06 (s, 2H), 1.13 (t, J=7.20 Hz, 3H); MS (ES) m/e 572 [M+H] + .
Example 78
N-ethyl-3-(4-{[(ethylamino)carbonyl]amino}phenyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazole-1-carboxamide
[0248] 1 H NMR (400 MHz, acetone-d 6 ) δ ppm 10.37 (s, 1H), 8.87 (s, 1H), 8.55 (s, 1H), 8.41 (d, J=5.31 Hz, 1H), 8.23 (t, J=5.81 Hz, 1H), 7.79 (s, 1H), 7.50-7.60 (m, 4H), 7.36 (d, J=7.83 Hz, 1H), 7.24 (t, J=7.83 Hz, 1H), 6.99 (d, J=5.56 Hz, 1H), 4.07-4.17 (m, 2H), 4.00 (t, J=11.75 Hz, 2H), 3.75 (d, J=11.37 Hz, 2H), 3.45-3.55 (m, 4H), 3.39 (s, 1H), 3.34 (s, 1H), 3.27 (q, J=7.07 Hz, 2H), 3.04-3.14 (m, 2H), 1.29 (t, J=7.20 Hz, 3H), 1.16 (t, 3H, J=7.2 Hz); MS (ES) m/e 585 [M+H] + .
Example 79
{3-(4-{[(dimethylamino)carbonyl]amino}phenyl)-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-1-yl}acetic acid
[0249] 1 H NMR (400 MHz, acetone-d 6 ) δ ppm 8.60 (s, 1H), 8.38 (d, J=6.06 Hz, 1H), 7.87 (s, 1H), 7.78 (d, J=8.59 Hz, 1H), 7.55-7.63 (m, 4H), 7.33-7.40 (m, 2H), 7.29 (t, J=7.71 Hz, 1H), 6.99-7.07 (m, 2H), 5.20 (s, 2H), 4.11 (s, 2H), 4.02 (s, 2H), 3.76 (s, 2H), 3.55 (s, 2H), 3.39-3.50 (m, 4H), 3.23-3.34 (m, 2H), 3.06 (s, 6H); MS (ES) m/e 572 [M+H] + .
Example 80
N-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-3-yl}-2-fluorophenyl)-1-pyrrolidinecarboxamide
[0250] 1 H NMR (400 MHz, acetone-d 6 ) δ ppm 11.35 (s, 1H), 8.55 (s, 1H), 8.44 (s, 1H), 7.93 (d, J=8.08 Hz, 1H), 7.61 (s, 1H), 7.56 (dd, J=12.25, 1.89 Hz, 3H), 7.38 (s, 1H), 7.26 (t, J=7.83 Hz, 1H), 7.21 (s, 1H), 6.98 (s, 1H), 4.30-4.39 (m, 2H), 4.15 (s, 2H), 4.03 (s, 5H), 3.74 (s, 2H), 3.57 (d, J=2.78 Hz, 2H), 3.56 (s, 2H), 3.40-3.48 (m, 2H), 3.33 (s, 2H), 2.95 (s, 2H), 2.01 (d, J=2.53 Hz, 4H), 1.51-1.61 (t, J=4.40 Hz, 3H); MS (ES) m/e 585 [M+H] + .
Example 81
N-(4-{1-ethyl-4-[2-({3-[2-(4-morpholinyl)ethyl]phenyl}amino)-4-pyrimidinyl]-1H-pyrazol-5-yl}-2-fluorophenyl)-1-pyrrolidinecarboxamide
[0251] 1 H NMR (400 MHz, acetone-d 6 ) δ ppm 11.58 (s, 1H), 8.37 (td, J=8.34, 2.53 Hz, 1H), 8.29 (s, 1H), 8.27 (d, J=6.32 Hz, 1H), 7.54 (d, J=2.27 Hz, 1H), 7.52 (s, 1H), 7.33-7.41 (m, 1H), 7.32 (d, J=1.77 Hz, 1H), 7.23-7.29 (m, 2H), 7.13 (d, J=7.58 Hz, 1H), 6.72 (d, J=6.4 Hz, 2H), 4.09 (q, J=7.16 Hz, 4H), 3.95 (t, J=12.13 Hz, 2H), 3.76 (d, J=11.87 Hz, 2H), 3.52-3.61 (m, 6H), 3.32 (t, J=10.61 Hz, 2H), 3.22-3.28 (m, 2H), 1.96-2.04 (m, 4H), 1.36 (t, J=7.20 Hz, 3H); MS (ES) m/e 585 [M+H] + .
[0000] General Synthesis of Amide Targets from Intermediate 33.
[0000]
Example 82
N-[4-(4-{2-[(3-{[4-(2-hydroxyethyl)-1-piperazinyl]methyl}phenyl)amino]-4-pyrimidinyl}-1-methyl-1H-pyrazol-3-yl)phenyl]-2,2-dimethylpropanamide
[0252] 33% as a yellow solid: 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.05-10.45 (m, 1H), 9.62 (bs, 1H), 9.29 (s, 1H), 8.32-8.30 (m, 2H), 7.71-7.70 (m, 1H), 7.69-7.68 (m, 2H), 7.65-7.64 (m, 1H), 7.43-7.42 (m, 2H), 7.25-7.13 (m, 2H), 6.63-6.62 (m, 1H), 3.95-3.92 (m, 5H), 3.81-2.90 (m, 13H), 1.24 (s, 9H); ESI MS m/z 569 [C 32 H 41 N 8 O 2 +H] + ; HPLC >99.0% (AUC), t R =9.65 min.
Example 83
2,2-dimethyl-N-{4-[1-methyl-4-(2-{[3-(1-pyrrolidinylmethyl)phenyl]amino}-4-pyrimidinyl)-1H-pyrazol-3-yl]phenyl}propanamide
[0253] 65% as a yellow powder: mp 218-223° C.; 1 H NMR (500 MHz, DMSO-d 6 ) δ 10.45 (s, 1H), 9.71 (s, 1H), 9.30 (s, 1H), 8.32 (t, J=2.8 Hz, 2H), 7.82 (s, 1H), 7.70 (d, J=8.4 Hz, 2H), 7.62 (d, J=8.1 Hz, 1H), 7.43 (d, J=8.6 Hz, 2H), 7.26 (t, J=7.8 Hz, 1H), 7.14 (d, J=7.6 Hz, 1H), 6.65 (d, J=5.2 Hz, 1H), 4.23-4.21 (m, 2H), 3.95 (s, 3H), 3.36-3.35 (m, 2H), 3.06-3.02 (m, 2H), 2.02-1.99 (m, 2H), 1.88-1.85 (m, 2H), 1.24 (s, 9H); ESI MS m/z 510 [C 30 H 35 N 7 O+H] + ; HPLC 98.1% (AUC), t R =10.5 min.
Example 84
N-(4-{4-[2-{(3-fluorophenyl)amino]-4-pyrimidinyl}-1-[2-(4-morpholinyl)ethyl]-1H-pyrazol-3-yl}phenyl)-1-pyrrolidinecarboxamide
[0254]
[0255] Step 1: To a solution of the pyrazole (40 mg, 82 μmol) in 3:1 CH 2 Cl 2 -pyridine (500 μL) at 0° C. was added methanesulfonyl chloride (10 μL, 100 μmol). The reaction was stirred at room temperature for 1.5 h. Analysis of the reaction mixture by LC-MS indicated the formation of the desired intermediate mesylate along with unreacted starting material. The reaction was cooled to 0° C. and additional methanesulfonyl chloride (10 μL, 100 μmol) was added and the reaction was stirred at room temperature overnight. LC-MS analysis of the reaction mixture indicated complete conversion of starting material.
[0256] Step 2: The reaction mixture from Step 1 was added dropwise to a solution of morpholine (500 μL, 5.7 mmol) in DMF (10 mL) containing potassium iodide (100 mg, 0.6 mmol) and potassium carbonate (1 g, 7.2 mmol) and heated at 50° C. for 4 h. The reaction was cooled to room temperature, poured into water (200 mL) and extracted with ethyl acetate (4×50 mL). The combined organic phases were washed with 5% lithium chloride solution (50 mL) and brine (50 mL), dried over sodium sulfate and purified by chromatography (silica gel, 0-10% MeOH/CH 2 Cl 2 containing 2% NH 4 OH) to afford Example 76 (20 mg, 44%) as a white solid. mp 167-168° C.; 1 H NMR (500 MHz, DMSO-d 6 ) δ 9.71 (s, 1H), 8.33-8.32 (m, 1H), 8.29 (m, 1H), 8.18 (m, 1H), 7.68-7.65 (m, 1H), 7.57-7.56 (m, 2H), 7.46-7.44 (m, 1H), 7.36-7.34 (m 2H), 7.21-7.19 (m, 1H), 6.70-6.67 (m, 1H), 6.64-6.63 (m, 1H), 4.32 (m, 2H), 3.57 (m, 4H), 3.37 (m, 4H), 2.79-2.77 (m, 2H), 2.50-2.46 (m, 4H), 1.85 (m, 4H); ESI MS m/z 557 [C 30 H 33 FN 8 O 2 +H] + ; HPLC >99% (AUC), t R =10.66 min. | The present invention provides a compound represented by Formula (I):
or a salt thereof, or a solvate thereof, or a combination thereof, wherein the substituents are as defined herein.
The present invention also relates to a composition comprising the compound of formula (I) and diluents, carriers, or excipients. Furthermore, the present invention relates to a method of treating a disease of cell proliferation comprising administering to a patient in need thereof a pharmaceutically effective amount of the compound of formula (I) or a salt thereof, or a solvate thereof, or a combination thereof. | 2 |
.Iadd.This is a continuation of application, Ser. No. 05/949,384, filed Oct. 6, 1978, now abandoned, which is a reissue of application Ser. No. 05/157,433, filed June 28, 1971, U.S. Pat. No. 3,819,468. .Iaddend.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application briefly describes, but does not claim, a method and apparatus for welding which is more fully described and claimed in U.S. Pat. No. 3,706,870 issued Dec. 19, 1972, in the names of the inventors Robert A. Sauder and Gary R. Kendrick and entitled "Method and Apparatus for Stud Welding".
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for insulating the interior of a high temperature furnace and more particularly to a ceramic fiber mat constituting the hot face of the insulation and wherein substantially all of the fibers in the fiber mat lie in planes which are generally perpendicular to the various walls of the furnace.
THE PRIOR ART
The problems involved in insulating the interior of a high temperature furnace or, stated differently, the walls and ceiling of such a furnace are well known. Historically, the interiors of high temperature furnaces have been lined with various types of bricks capable of withstanding these high temperatures. When the brick lining wears out, however, it is an arduous and time-consuming task to replace the old brick with a new brick lining. On the other hand, efforts have been made to insulate the interior of a furnace where the interior or hot face of the insulation includes or consists of ceramic fiber material. Ceramic fiber material, as referred to herein, is generally available in the form of a ceramic fiber blanket which is customarily manufactured in a manner similar to the conventional papermaking process. As such, the fibers which constitute the blanket, (as is also the case in connection with paper) are oriented in planes which are generally parallel to the longitudinal direction of formation of the blanket or sheet. When, as propossed in the past, lengths of ceramic fiber blanket are placed against a furnace wall or overlying an intermediate insulating member which, in turn, would be attached to the furnace wall, the fibers will then be lying in planes generally parallel to the furnace wall. Also, it is believed that a majority of these fibers will be lying in a direction which would tend to be colinear with the direction of formation of the blanket itself, although a considerable number of fibers are still in a more or less random disposition in these planes. Nevertheless, where the fibers are disposed in planes which are parallel to the furnace wall, there is a tendency for the fiber blanket material to produce cracks which result from heat shrinkage.
With certain types of insulation it is recognized that high temperature problems sometimes involve melting, oxidation and other types of deterioration of the insulating medium. As far as ceramic fiber insulation is concerned, the high temperature problems are generally cracking, delamination (peeling off of the surface layers), and devitrification, all of which are believed to be interrelated. At the lower temperatures of the recommended range of the present invention, namely, 1600° to 2800° F., devitrification will take place relatively slowly, whereas at the higher end of the range, devitrification will take place quite rapidly, followed, in short order, by cracking and/or delamination.
In retrospect, the prior art broadly discloses the feature of re-orienting fiber insulation, but only in connection with low temperature insulation. For example, Di Maio et al. U.S. Pat. No. 2,949,593 and Slayter U.S. Pat. No. 3,012,923 both show the cutting of strips of fibrous material from a sheet or mat of the same, arranging the strips in a side-by-side relation to provide an end fiber exposure, compressing the strips and, while still compressed, applying an adhesive backing sheet of paper or cloth to one side edge only of the resulting compressed block; thereafter when the forces of compression are removed the resulting block will tend to curl around the adhesive sheet so as to form a suitable insulating body for pipe or the like. However, the resulting insulation is necessarily low temperature insulation because the pipe is in direct contact with the heating or cooling medium which it carries; the insulation is used on the exterior surface of the body or pipe to be insulated; the sole purpose in arranging the strips in an end or edgewise exposure of the fibers is to permit compression of the strips so that, after one side edge is secured in place by means of the backing strip, advantage can be taken of the relatively greater expansibility along the unsecured edge.
SUMMARY OF THE INVENTION
The present invention involves the use of a ceramic fiber mat which can be applied either directly to the interior of a high-temperature furnace or to an intermediate insulating member which, in turn, is attached to one of the furnace walls. The term "wall" should be construed as covering any side wall or ceiling, removable or fixed, the area surrounding any access opening and any other surface on the interior of the high-temperature chamber where insulation is required or desired. The term "furnace" should be construed as covering any high-temperature chamber, oven, heater, kiln or duct with the understanding that the insulation is always internal and always "high-temperature", namely capable of operating at temperatures in excess of 1600° F.
The ceramic fiber mat is preferably made up of strips which are cut transversely from a length of ceramic fiber blanketing which is commercially available. The strips are cut from the fiber blanket in widths that represent the linear distance from the cold face to the hot face of the insulating fiber mat. The strips which are cut from the blanket are placed on edge and laid lengthwise adjacent each other with a sufficient number of strips being employed to provide a mat of the desired width. Naturally, the thickness of the fiber blanket from which the strips are cut will determine the number of strips required to construct the mat. The strips can be fastened together by wires, or by ceramic cement or mortar which is preferably employed in the region of the cold face of the mat. The mat can be applied to the furnace wall or to an intermediate member by means of a stud welding method or by ceramic cement, mortar, or the like.
As disclosed herein, the present invention has particular application for the internal insulation of furnace walls of high temperature furnaces. For the purposes of the present invention, "high temperature" will mean temperatures in excess of 1600° F. and, preferably, in the range of 1600° F. to 2800° F. The ceramic fiber strips referred to herein are cut from a ceramic fiber blanket which is commercially available from several different manufacturers; these blankets are manufactured under the trademarks or tradenames "Kaowool" (Babcock & Wilcox), "Fiber-Frax" (Carborundum Co.), "Lo-Con" (Carborundum Co,), and "Cero-Felt" (Johns Manville Corp.). Most of these ceramic fiber blankets have an indicated maximum operating temperature of about 2300° F. The end or edge fiber exposure provided by the present invention not only provides an improved insulation up to the maximum indicated operating temperatures suggested by the manufacturers, but because devitrification and its deleterious effects are largely eliminated, also permits operation up to about 2800° F.
By arranging the fibers in an end or edgewise exposure; that is, where the fibers are oriented in planes generally perpendicular to the wall of the furnace, devitrification is not necessarily avoided but its undesirable side effects are minimized or eliminated because devitrification takes place at the ends of the fibers rather than along the lengths thereof; thus cracking and delamination are essentially avoided by the present invention even up to a temperature of 2800° F. which is above the recommended maximum temperature specifications imposed upon the fiber blankets by the manufacturers.
The present invention also provides an insulation which will maintain the outside (cold face) of the furnace within an acceptable range. It is recognized that the minimum external temperature will be dependent upon a number of different factors including, but not limited to, the type, thickness and strength of the outside furnace wall; ambient temperature conditions outside the furnace wall. The use of the present invention, however, will provide an outside temperature varying between 200° and 350° F. which is considered to be an acceptable range, the temperature being measured in still air at 83° F.
Another advantage which accrues from the use of the fiber blanket (or strips thereof) in the end or edge exposure of the fibers is that the resulting mat has a certain resiliency in a direction parallel to the insulated face. Thus, where metallic fasteners are employed to attach the mat or composite block to the interior wall of the furnace or oven by "burying" or imbedding the fastener in the insulating member, this natural resiliency of the material will tend to keep the ends of the fastening elements completely covered at all times; this is true even if a tool is inserted in or through the fiber material to engage the metallic fastener for turning or welding purposes; after the tool has been withdrawn the natural resiliency of the fibrous material, as presently oriented, will cause the material to spring back and completely cover the outer end of the metallic fastening member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary plan view of an insulating mat made from strips of a ceramic fiber blanket;
FIG. 2 is a fragmentary side elevation of the ceramic fiber mat shown in FIG. 1;
FIG. 3 is an end elevation of the ceramic fiber mat shown in FIG. 1;
FIG. 4 is a plan view of another embodiment of a ceramic fiber mat made in accordance with the present invention;
FIG. 5 is a side elevation of the ceramic fiber mat shown in FIG. 4 with certain internal connecting members shown in dotted lines and further showing the association of the resulting insulating member with a furnace wall;
FIG. 6 is an end elevation of the ceramic fiber mat shown in FIG. 5;
FIG. 7 is a view similar to FIG. 6 showing a method of stud welding of the resulting insulating member to a furnace wall;
FIG. 8 is an enlarged and fragmentary detail view, with certain parts in cross-section, of the stud, nut and associated structure involved;
FIG. 9 is a view similar to the lower portion of FIG. 8 showing the relationship of the various parts following the welding operation;
FIG. 10 is an enlargement, on a slightly larger scale, of the retaining ring shown in FIG. 8;
FIG. 11 shows a parquet-type arrangement of insulating members on a furnace wall;
FIG. 12 shows an enlargement of insulating members on a furnace wall with spaces between adjacent members being filled with separate insulating elements;
FIG. 13 shows one embodiment of a separate insulating element to be inserted between adjacent insulating members;
FIG. 14 is another embodiment of a separate insulating element to be inserted between adjacent insulating members; and
FIG. 15 is still another embodiment of a separate insulating element to be inserted between adjacent insulating members.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in detail, FIG. 1 shows a portion of the outer surface (hot face) of an insulating mat, generally designated by the reference character 20, composed of a plurality of strips 22 which are cut transversely from a ceramic fiber blanket (not shown). As indicated heretofore, these ceramic fiber blankets are generally provided in widths of several feet, of thicknesses generally ranging from one-sixteenth of an inch to three inches and of almost any desired length; the manufacturer generally rolls up the blankets lengthwise so that, when supplied, these blankets are in the form of rolls whose diameters are dependent upon the length of material in the roll. When the strips 22 are cut from the fiber blanket they are cut in a direction of the thickness perpendicular to the width and length so that the lowermost strip 22 shown in FIG. 1 has a dimension T which represents the thickness of the fiber blanket from which the strips 22 are cut.
The strips 22, after they are cut from the fiber blanket, are placed on edge adjacent each other until the desired width of mat is obtained as shown in FIG. 1. Obviously, the number of strips required will depend upon the thickness T of the fiber blanket from which the strips are cut. If a fiber blanket could be provided of thickness twice that of T, then only one half of the number of strips shown in FIG. 1 would be required. Furthermore, if it were possible to provide a fiber blanket having a thickness equal to the width of the resulting block or mat therefor, then only one such strip would be employed in connection with each insulating block.
The strips 22 are held together by any convenient means; as best shown in FIGS. 1 to 3, the strips 22 are held together by means of a plurality of stainless steel wires 24 which run transverse to the strips approximately one-half inch from and parallel to the cold face 26 of the mat. The ends of the wires 24 are bent at right angles as shown so as to be retained in position. Various methods and means can be used in conjunction with these wires 24 to attach the mat 20 to a sheet or block of backing type insulation 28 (see FIGS. 5 and 6); for example, a plurality of hairpin-type devices 30 can be placed over the wires 24 at various positions along their length so as to project down below the cold face 26 of the mat 20. Actually, these pins 30 will be driven into the block of backing type insulation 28 and, preferably, these hairpin devices 30 will be of the self-clenching type when they are urged against a hard surface as will appear hereinafter.
Although the mat shown in FIGS. 1 and 2 (and the resulting insulation member comprised thereof) is represented as having a width of approximately one foot and a length of possibly several feet, the preferred shape is shown in FIGS. 4 to 7. The resulting insulating member shown in these figures would have a nominal twelve inch by twelve inch face size and a 2300° F. temperature rating. The actual face size will be 121/4"×121/4", the additional 1/4" insuring fullness in the installed insulation while providing a net twelve inch by twelve inch coverage. Intermediate strips 22' and the outer strips 34 (later to be described) are cut to their respective sizes from one inch thick ceramic fiber blanket. The block of insulation 28 is mineral block insulation which, in this case, is cut to a size two inches thick, ten inches wide and twelve inches long. Since the outer strips 34 overlie the longitudinal side edges of the block 28, these strips would be two inches longer (in the vertical direction as they appear in FIG. 7) than the intermediate strips 22'. It might also be mentioned that a hole 36 is drilled in the center of the block 28 so as to receive a stud (later to be described).
Parts 34 and 22' are not laid side by side to form the hot face and are secured together by means of the stainless steel wires 24 which are bent ninety degrees at the ends to hold them in place. As shown in FIGS. 4 and 5, two such wires 24 are provided for the insulating member shown in these figures, although additional number of wires could be provided if desired.
The next step in the assembly of the insulating member involves the installation of the stud which will now be described. The stud comprises a central shank 38 having nut 40 threadedly mounted at the upper end thereof. A washer 42 is provided on the shank 38 immediately below the nut 40. When installed, the washer 42 will rest against the upper surface of the block 28. The lower end of the shank 38 is provided with a stud tip 44 of relatively smaller cross sectional area. Also mounted on the lower end of the shank 38 are a ring retainer 46 received in the groove 48 and a ring-shaped ceramic arc shield 50 which is secured to the ring 46 by cement or in any other suitable manner. The purposes of the foregoing elements will be described hereinafter in greater detail.
At any event, after the stud (with associated elements attached) is inserted into the hole 36 in the manner described above, the prior assembly of parts 22', 34 and 24 are placed over the block 28 with the lower parts of the side strips 34 overlying the two longitudinal side edges of the block 28. Four hairpin-type stainless steel fasteners 30 (two for each wire 24) are now inserted into the seams between the strips 22' so as to engage the wires 24. These fasteners 30 are driven through and clenched against the back surface of the block 28. By providing a hard surface, preferably steel, below the block 28 when the fasteners 30 are inserted, the lower ends of these fasteners will clench towards each other as shown in FIG. 5. When the tool (not shown) for inserting the fasteners 30 is withdrawn from the seams, the strips 22' will return to their original position without leaving any gap or aperture because of the inherent resiliency of these strips.
The resulting insulation member, now complete, is ready for installation against a furnace wall 32 by means of a stud welding process which is more fully described and claimed in the patent entitled "Method and Apparatus for Stud Welding" referred to above. The method and apparatus for stud welding (as described in the aforementioned copending application) forms no part of the present invention but is described briefly hereinafter merely to show one manner of attachment of the insulating member 20' to a furnace wall. A stud welding gun 52 is inserted into the central seam between the middle strips 22' until the lower end of the sun engages the nut 40 of the stud. The stud gun is triggered and current flows into the shank 38 and into the tip 44. The tip 44, because of its relatively small cross sectional area burns away and thus starts an arc. The stud shank 38 does not itself move at first because it is supported by the self-locking ring retainer 46 which is retained in the groove 48 as indicated heretofore. As best shown in FIG. 10, the ring retainer 46 is provided with a plurality of radial fingers 54 which project into the recess 48 to hold the ring 46 in position. As the welding operation continues, the intense heat of the arc burns away the fingers 54, thus allowing the stud shank 38 to plunge into the molten metal formed by the arc. At this point, the weld is completed and the gun can be withdrawn. It should be mentioned, however, that the ring retainer 46 and the fingers 54 thereon are carefully sized so that the fingers will burn away, melt, or soften in approximately two tenths of a second, or within whatever period of time is deemed appropriate, all as set forth more fully in the aforementioned copending application.
Now, it may be desirable to tighten the nut 40 on the shank 38. This can be done by merely rotating the gun about the vertical axis of the shank. It might be mentioned that the lower end of the gun (or extension thereof, if desired) is provided with a hexagonal opening corresponding to the size of the nut 40 and of sufficient depth to accommodate for the upper end of the shank 38 after the nut is tightened thereon. Thus the gun 52 serves a secondary function as a wrench for the nut. When the stud gun is withdrawn, the resiliency of the ceramic fiber strips will cause the strips to return to their original position thus concealing and protecting the studs from the severe heat in the furnace.
Returning now to further consideration of FIGS. 4 and 5, it should be noted that the end strips 34 of the insulating member 20' are preferably provided with a plurality of one inch deep cuts 56 spaced approximately one inch apart from each other so as to relieve possible shrinkage stresses on parts 34 only.
As shown in FIG. 11, it may be desirable to arrange the blocks 20' of FIGS. 4 through 6 in such a manner that the strips of adjacent members are at right angles to each other to give a resulting criss-cross appearance similar to that of parquet flooring. As indicated heretofore, the arrangement of the fibers is such that they are oriented essentially in planes which are perpendicular to the furnace wall. This tends to eliminate or minimize the occurance of cracks which result from heat shrinkage of ceramic fibers. The arrangement shown in FIG. 11 tends to minimize or offset lineal shrinkage of the strips themselves.
The method and apparatus for insulating a furnace wall must be adaptable to walls which do not correspond, dimensionally, to the usage of nominal twelve inch by twelve inch insulating members. Also, it is recognized that the method and apparatus for insulating a furnace should be adaptable to furnaces which have irregularly shaped burner blocks and flue openings. As shown in FIG. 12, it is possible to arrange and attach a plurality of insulating members 20' to the surface 32' of a furnace not readily adaptable for the close end-to-end, side-to-side, arrangement shown in FIG. 11. In the case of FIG. 12, spaces 58 are provided between adjacent insulating members 20' in longitudinal or transverse or both, directions, depending upon the dimensional limitations of the furnace. The resulting spaces 58 can now be filled with specially folded ceramic fiber blankets such as shown in FIGS. 13, 14 and 15. The three fillers shown in the latter three figures are constructed in substantially the same way as the strips 22; that is, they are cut from a one inch thickness of four pound density ceramic fiber blanket and folded over.
In FIG. 15, there would be a single sheet 60 which is folded once so that its upper edges 62 provide the same type of end or edge fiber exposure referred to herein. If the resulting space is larger than two inches wide, then it is possible to go to the configuration shown in FIG. 13 which is comprised of two strips 64 and 66, which are cut in the same manner described above. The central strip 66 is relatively narrow in a vertical direction and the outer strip 64 is sufficiently wide that it can be folded around the central strip 66 as shown, the upper surfaces of strips 64 and 66 both providing the end or edge fiber arrangement referred to above.
Again, if the resulting space between adjacent insulating members 20 are between an insulating member 20 and a duct, etc. is greater than three inches, then it might be desirable to use the configuration shown in FIG. 14 where an additional central strip 68 is provided. This strip 68 will lie adjacent the strip 66 and an outer strip 70, slightly greater in width than the strip 64 will be folded over the central strips 66 and 68 to provide the arrangement shown.
The different embodiments shown in FIGS. 13, 14 and 15 can be held in place by ceramic cement, stainless steel wire or by the friction between the fibers alone.
FURTHER EMBODIMENTS AND MODIFICATIONS
Whereas the method of assembling the mat as described in relation to FIGS. 1 to 3 has been set forth in terms of wires 24, fasteners 30, etc. it should be understood that other methods could be employed to hold the strips together and to attach them to the backing insulation block. For example, the ceramic fiber strips could be attached to each other by means of suitable ceramic cements or mortar materials which are preferably utilized in the area adjacent the cold face of the fiber mat. Also, although the mats have been shown as being connected to a backing insulation block prior to application to a furnace wall, the mats could be applied directly to the furnace wall.
As far as the manner of fastening is concerned, the foregoing disclosure indicates that the mat of FIG. 1 or the composite block of FIG. 4 can be attached to a furnace wall by means of mortar, ceramic cement or various metallic fasteners. Since the ceramic cement or mortar will generally be located adjacent the cold face of the insulating member, there should be no particular high temperature problem as far as the cement or mortar is concerned; however, where metallic fasteners are concerned, it is generally recognized that alloy pins, bolts, washers and screws which could be used as fasteners have a maximum temperature limit in the range of 2000° to 2100° F. By "burying" or imbedding the fastener in the insulating member at a position spaced from the hot face thereof, as disclosed in the present invention, it is possible to use alloy pins, bolts, etc. without, at the same time, exposing these metallic fasteners to such high temperatures as would interfere with their effectiveness.
Although it is indicated that the mat of FIG. 1 could be applied directly to a furnace wall by means of ceramic cement or mortar, it is possible to precondition the cold face of the mat to permit the use of the stud welding method of attachment disclosed herein. For example, if a layer of cement or mortar is embedded in the mat along the cold face thereof and allowed to harden, it is obvious that the welding technique and fasteners described in connection with FIGS. 7 to 10 could be employed, although a shorter shank 38 obviously would be necessary. The making of such a cement or mortar layer at the cold face of the mat could also be done in connection with the use of a high temperature cloth or stainless steel wire mesh which would be applied to or imbedded in the mortar layer at the cold face of the mat to improve the fastening capabilities thereof.
Referring now to FIGS. 4 through 7, a suitable insulating block 20' designed for operation at 1800° F. is one where the backing block or mineral block 28 is about two inches in thickness and the strips 22' are approximately one inch in width giving a total width of the block, from the cold face to the hot face thereof, of about three inches. A suitable insulating block 20' designed for operation at 2600° F. is one where the mineral block 28 is also two inches in thickness but where the strips 22' are four inches in thickness giving an overall dimension of six inches from the cold face to the hot face. By using strips 22 varying in width from one inch to five inches or more, depending upon the requirements of the particular furnace, it should be apparent that insulating blocks and/or mats could be employed to cover the recommended range of 1600° F. to 2800° F.
Although the block 28 has been referred to as a mineral block whose composition and properties are well recognized in the art, it is also possible to use asbestos block or calcium silicate block, these blocks being relatively rigid, especially as compared to the fiber mat or strips, so as to provide relatively rigid backing material for the mat. The strips 22 or 22' of the ceramic fiber mat 20 or 20', respectively, are preferably cut from a ceramic fiber blanket having a density of four pounds per cubic foot. It is understood that the manufacturers provide ceramic fiber blankets which are available in densities ranging generally from three to fourteen pounds per cubic foot. In the specific examples referred to herein, the ceramic fiber material has a density of four pounds per cubic foot. However, it should be understood that there might be portions of the furnace where the lining would be subject to gas currents which would give rise to erosion problems and, also, that the furnace might have various access openings which would require a lining of greater physical strength or density upon or surrounding the openings; in either of the latter two cases it might be desirable to use a ceramic fiber material of a higher density in the available range referred to above.
Naturally, it is desirable to insulate a furnace wall in such a manner that the outside (cold face) of the furnace is at a minimum temperature. However, it is recognized that this minimum temperature will be dependent upon a number of different factors including, but not limited to, the type, thickness and strength of the outside furnace wall; and prevailing air currents outside of the furnace wall. The use of the present invention will provide an outside temperature varying between 200° F. and 350° F. which is considered to be an acceptable range.
The preferred embodiment of the present invention, as disclosed above, describes the high-temperature insulating fibers which constitute the mat as "ceramic" fibers. However, this invention should not be tied down to any precise definition of "ceramic"; any high temperature insulating fiber which possesses properties similar to the ceramic fibers indicated herein and capable of operating above 1600° F. could be used in conjunction with the present invention and should be considered as falling within the scope thereof.
Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein may be made within the spirit and scope of this invention. | A ceramic fiber mat attached to the interior wall or surface of a high temperature chamber or furnace or adapted to overlie an intermediate insulating member positioned between the mat and a furnace wall, the fibers in the mat lying in planes generally perpendicular to the wall, the mat constituting an improved insulation for the wall where the interior of the chamber or furnace will be operating at temperatures in excess of 1600° F. | 8 |
PRIORITY CLAIM
The present application is a continuation to U.S. patent application Ser. No. 09/873,943, filed Jun. 4, 2001 now U.S. Pat. No. 6,914,970, the entirety of which is incorporated by reference herein.
FIELD OF THE INVENTION
The invention relates to a system and method for a user to monitor and override a backup call receiving system or service to which an incoming telephone call intended for the user has been forwarded.
BACKGROUND
A call to a telephone user is sometimes forwarded to a service such as messaging service or assisting agent service. Such services are typically provided by a telephony service system external to the switch that serves the user's telephone line. Compared to a home answering machine, these service systems may be advantageous since they can provide more storage capacity and enable record tracking and post-call processing such as information redistribution.
Unlike the home answering machine, however, these service systems typically do not provide a way for the user to listen to the forwarded call while the interaction between the caller and the service system is in progress, e.g., while the caller is leaving a message with a messaging service system. Thus, the user cannot monitor and/or override the handling of the call like they would be able to do on a home answering machine. Yet, the user of the messaging service or assisting agent service often desires such monitoring and/or overriding of the service.
Some switch vendors provide a screening function from a serving switch which alerts the user about a call intercepted by a messaging or attendant system, and allows the user to screen the call. The cost of this switch function, however, is typically prohibitive. Another difficulty of the switch approach is that a switch operator cannot determine whether a call has been forwarded to a backup service system for which screening options are desired, or to another destination where such options are not desired. Moreover, most switches today do not include a call screening function and the call screening function is not available to users and/or call backup service providers served by such switches.
Thus, there is a need for an improved call monitoring and overriding system and method to handle the calls forwarded to a service system.
BRIEF SUMMARY
A system and method are disclosed for a user to monitor on a call-by-call basis a call forwarded to a system or service, such as a remote messaging system. In addition, the user may elect to override the service to which the call has been forwarded, i.e., to connect to the caller and disconnect the system service. Typically, the forwarded call was initially an incoming call from a calling party to the user and thereafter forwarded to a remote service system. Since the service system is remotely located, the user cannot otherwise screen the forwarded call as he or she could with a home answering machine. A monitoring and service system overriding function can be added as a component of the service system or it can be an independent subsystem used in conjunction with the service system.
Thus, after an incoming call is forwarded, the monitoring and service system overriding function determines a redirecting number of the user from which the incoming call was forwarded. The monitoring and service system overriding function then initiates a second call to the user and establishes a one-way voice path connecting the forwarded call to the second call. Thereafter, the user is notified, for example, with a distinct ring at the user's telephone, that the user may monitor the forwarded call via the established one-way voice path. The user may pick up the phone to do so, and may then choose to connect directly to the caller via a two-way voice path, and disconnect the forwarded call from the remote service.
Further aspects and advantages of the invention are discussed below in conjunction with the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an exemplary system for providing a monitoring and service system overriding feature according to the preferred embodiments.
FIG. 2 is a block diagram of an alternate system for providing the monitoring and service system overriding feature according to the preferred embodiments.
FIG. 3 is a state diagram illustrating the functionality of an application that provides the monitoring and service system overriding feature according to the preferred embodiments.
DETAILED DESCRIPTION
A call monitoring and service system overriding system is provided in a communication environment that allows a system user (“user”) to monitor and, at the user's option, connect to a call that has been forwarded to a remote service system. The remote service system may be, for example, a backup system such as a messaging system, an answering service, a third party's phone and a unified messaging system. For simplicity of description, the term telephone system is used herein where the term communication environment could also be used. Also, the term telephone line is used herein, where the term communication line could be otherwise used. The telephone line can be a line shared by telephone and data network access services, or can be another telephone line, or other lines, physically or logically separate.
FIG. 1 illustrates a communication environment, such as telephone system 100 . The telephone system 100 connects via telephone lines a calling party (“caller”) 110 to a called party, i.e., a user 120 of monitoring and overriding service. A serving switch 130 connects a calling party telephone line 125 to the called party's telephone line 123 to direct an incoming call from the caller 110 to the user 120 .
When the user's telephone is busy, the user does not otherwise answer the incoming call, or as set up by the user, the incoming call is forwarded to a remote service system 140 . Telephony trunks capable of conveying caller and redirecting numbers, such as Integrated Services Digital Network (ISDN) trunks, connect the serving switch 130 to the remote service system 140 . The remote service system 140 includes a message system, for example, voice-mail, and an answering service automatic call distribution system, such as when a call center agent answers the forwarded call and takes a message. Other types of remote service systems 140 could also be used, such as, automatically sending the call to a third party's phone, e.g., a colleague's phone, or sending the call to a unified messaging service. The unified messaging service is a service that allows for the storage and retrieval of message in various media formats and that, for example, converts an e-mail text message to a voice message or vice versa.
To provide for the monitoring and service system overriding service without a screening function included in the serving switch, a bridge and control component 150 is added to the remote service system 140 . The bridge and control component 150 determines if the called party of a given forwarded call has the monitoring and/or overriding service registered and activated. The bridge and control component 150 also alerts the user about the monitoring opportunity. The bridge and control component 150 bridges the user 120 into the monitoring session and can detect the user's intention to override the service system. If the user 120 indicates a desire to override the service system, the bridge and control component 150 sets up two-way voice path between the caller and the user and requests the serving switch 130 to directly connect the caller 110 and user 120 . The user 120 can signal his or her election to override the forwarded call by, for example, pressing a telephone key or speaking into the telephone handset.
FIG. 2 shows an alternate communication environment, such as telephone system 200 , that also uses the call monitoring and overriding service of the preferred embodiments. The caller 110 connects to the user 120 via the telephone system 200 . Telephone line 125 connects the caller 110 to the serving switch 130 and the serving switch 130 connects the caller 110 to the user 120 via the telephone line 123 . Unlike the configuration shown in FIG. 1 , the serving switch 130 is not directly connected to the remote service system 140 , but connects through a bridge and control subsystem 210 . The bridge and control subsystem 210 contains hardware, software, and data necessary to accomplish the monitoring and service system overriding functions of the forwarded call without modifying the original remote service system 140 . The bridge and control subsystem 210 functions similarly to the bridge and control component 150 in FIG. 1 .
FIG. 3 shows a state diagram illustrating an application 300 that enables call monitoring and service system overriding functions according to the preferred embodiments. It should be noted that this diagram depicts a state machine for a single user handled by the monitoring and service overriding function, but the function can simultaneously handle multiple independent users. The application 300 includes a program or process that resides on software, firmware or hardware, or combinations thereof. The application preferably resides with the bridging and control function as a subsystem 210 or as a component 150 in the remote service system 140 .
To utilize the monitoring and overriding service, the user 120 preferably registers via a registration procedure. The registration procedure records that the user desires the ability to monitor and override calls forwarded from their telephone line 123 . The user 120 preferably can also deregister from the monitoring and overriding service, and can activate or deactivate the service when registered. Various mechanisms can be used to register with or deregister (or activate or deactivate) from the monitoring and overriding service, including the user manually registering or deregistering with the service using a telephone. Other methods for registering and deregistering the user 120 could also be used, such as the user 120 using a world-wide web session to register with or deregister from the service.
Returning to FIG. 3 , at state 310 , the application 300 resides in an idle state before a call is forwarded to the remote service system 140 . At block 320 , the call arrives at the bridging and control subsystem 210 or component 150 with the condition that the called party is not registered as a monitoring service user 120 or the user has deactivated the monitoring service. In this case the service system interacts with the caller 110 normally, and the monitoring and overriding service is not invoked. The application 300 remains at the idle state (state 310 ).
In a preferred embodiment, to determine whether the called party is registered with the service and the service is activated, call-processing logic located at the bridging and control subsystem 210 or component 150 determines the called party's telephone number. For example, the call-processing logic can recognize a redirecting number in a call-setup-signaling message, which is the called party's telephone number. Thereafter, the called party's telephone number is compared with active registered users' telephone numbers to determine whether the called party is registered for the monitoring and overriding service.
At block 330 , a call arrives at the bridging and control subsystem 210 or the remote service system 140 and the called party is a registered and active user 120 . The application 300 initiates a second call to the user's telephone line 123 and connects the second call with the caller 110 via a one-way voice path. The one-way voice path allows the voice of the caller 110 to be audible to the user 120 without making the user's voice audible to the caller 110 . The user 120 can be notified of the second call with a distinct ring as directed by the application 300 and provided by the serving switch 130 . If the telephone line of user 120 is equipped with a caller identification (ID) device, the calling party's telephone information may appear as provided by the bridging and control subsystem 210 or component 150 .
At state 335 , the application 300 waits for a user interaction or for a timeout to occur while the caller 110 leaves a message with the remote service system 140 and the second call is being sent to the user 120 . At block 340 , when the user 120 fails to answer the second call before a determined time out period elapses or the caller 110 disconnects from the call, the application terminates the one-way voice path connection with the caller 110 and returns to the idle state (state 310 ).
At block 350 , the user 120 answers the second call upon receipt of the second call. Thereafter, the user 120 can listen to the forwarded call, e.g., the interaction between the caller 110 and the remote service system 140 via the one-way voice path. The voice path can be implemented by the bridge and control subsystem 210 or the bridge and control component 150 . Those skilled in the art with appreciate that that voice path can be implemented in other ways, such as with digital signaling processing and packet voice transmission and processing. At state 355 , the application 300 waits while the user 120 monitors the caller's call to the remote answering service 140 .
Upon listening to the caller 110 , the user 120 can elect to override the forwarded call or disconnect from the call. At block 360 , if the user 120 disconnects from the forwarded call or the caller interaction with the remote service system 140 ends, the application 300 terminates the one-way voice path and enters the idle state (state 310 ).
At block 370 , the user 120 elects to override the forwarded call. The user 120 can signal his or her election to override the forwarded call by, for example, pressing a telephone key or speaking into the telephone handset. The user may speak a command into the telephone handset or merely say anything, depending on how the application 300 is set up. The application 300 , upon detecting the pressed key or the user's voice, provides a two-way voice path between the user 120 and the caller 110 . The application 300 also preferably detaches the caller 110 from the remote service system 140 , for example, the recording or attendant leg of the forwarded call.
The bridge and control subsystem 210 or component 150 can request the serving switch 130 to bridge out the forwarded call and connect the caller 110 directly with the user 120 . At block 375 , the application 300 waits for the serving switch 130 to bridge out. At block 380 , when the serving switch 130 bridges out the forwarded call and connects the caller 110 directly with the user 120 , the application 300 can return to the idle state (state 310 ). The application 300 also returns to the idle state (state 310 ) if the caller 110 or the user 120 disconnects from the call before the bridging out occurs.
While the invention has been described above by reference to various embodiments, it will be understood that many changes and modifications can be made without departing from the scope of the invention. It is therefore intended that the foregoing detailed description be understood as an illustration of the presently preferred embodiments of the invention, and not as a definition of the invention. It is only the following claims, including all equivalents, which are intended to define the scope of this invention. | A system and method are disclosed for a user to monitor and/or override a forwarded call. Typically, the forwarded call was initially an incoming call from a caller to the user and thereafter forwarded to a remote service system, such as a remote messaging system. The system and method determine a redirecting number from which the incoming call was forwarded. The system and method then initiates a second call to the user and a voice path is established connecting the forwarded call to the second call. Thereafter, the user is notified, for example, with a distinct ring at the user's telephone, of the option that the user may monitor and override the forwarded call. The system and method can also execute procedures to actuate the options elected by the user. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of medicine, veterinary medicine, molecular biology, immunology and biotechnology, specifically, to the development of vaccines and adjuvants therefor, and treatments. The field of application of this invention mainly corresponds to the fish farming industry. More specifically, this invention relates to a viral RNA expression plasmid and a method for obtaining viral particles based on said plasmids.
BACKGROUND OF THE INVENTION
[0002] Infectious salmon anemia (ISA) is a disease that mainly affects Atlantic salmon (Salmo salar) causing huge losses in salmon farming worldwide (1, 14). The clinical signs of this disease are the presence of pale gills, ascites, hemorrhagic necrosis of the liver, splenomegaly, congestive gut and acute anemia (14). ISA was first reported in Norway in 1984 (28), later diagnosed in Canada (4), Scotland (27), United States (18), Faroe Islands (18) and Chile (16).
[0003] The etiological agent of this disease is a packaged pleomorphic virus between 45 and 140 nm of diameter, called Infectious Salmon Anemia Virus (ISAV), belonging to the Orthomixoviridae family (8). Its genome consists of 8 ssRNA of negative polarity (ns-RNA) that encode for 10 proteins and which have Untranslated Regions (UTRs) at both ends (26).
[0004] There is a limited knowledge about the functions of each ISAV protein performs. Bioinformatics evidence indicates that segments 1, 2 and 4 would encode for dependent RNA polymerase subunits (RpRd), analogous to PB2, PB1 and PA of Influenza A virus, respectively. Segment 3 encodes for NP protein, which has been reported to have the ability to bind ssRNA (2). As for Influenza, it has been proven that these four polypeptides relate to each one of the eight viral RNA segments to form Ribonucleoprotein complexes (RNPs) (23). These eight RNP units correspond to the minimum infectious unit required to initiate a cell infection (23). Segment 5 encodes for the Fusion protein (F), which has shown to be present on the surface of the viral membrane, allowing at the first steps of the infection, the fusion of the membrane of the viral particle with the cell endosome, allowing the release of the RNPs into cell cytoplasm (3). Segment 6 encodes for hemagglutinin-esterase protein (HE), which is also present on the viral surface and whose function is to bind a sialic acid residue located in the cell receptor (15). HE protein also has receptor-destroying activity (RDE, receptor destroying enzyme), favoring the release of new viral particles emerging from the cell membrane (21). Contrary to what is observed in hemagglutinin from Influenza A virus, whose stalk region is highly kept, it has been reported that ISAV's HE protein has a highly variable region towards the carboxy terminal end and adjacent to the transmembrane region, also known as Highly Polymorphic Region (HPR) (9). This HPR region encodes for 35 amino acids and, based on its high polymorphism 30 variants have been described in Europe, North America and Chile (30, 31, 32). One theory explains this variation as a deletion phenomenon from an ancestral strain present in the longest HPR region that is called HPRO (33). The first HPRO strain was identified in Scotland in wild salmon that did not show any clinical signs of ISA, being classified as an avirulent strain (34). In contrast, those strains presenting deletions in that zone are capable of developing virulent ISA-related clinical signs and mortality. It is suggested that segment 7 encodes for non-structural proteins analogous to NS1 and NS2 of influenza A virus (19). Finally, segment 8 encodes for a transcript containing two overlapping open reading frames (ORF, Open reading Frame). ORF1 encodes for the matrix protein (M), and ORF2 encodes for M2 protein. It has been shown that M2 protein is involved in the modulation of the type-I IFN response in conjunction with the NS1 protein (12).
[0005] As regards the Influenza Virus, detailed study of the virus has been possible as a result of the development of a reverse genetics system, which allows to manipulate the virus genome, being able to determine possible causes of virulence, as well as detailed study of each one of the functions of viral proteins (13). The most widely used reverse genetics system on Influenza virus is the plasmid-based system which allows to generate recombinant viruses from cloned cDNA. ISA Virus has 8 genomic RNAs transcribed under control of RNA polymerase I and the proteins making up the ribonucleoprotein complex under the command of RNA polymerase II are expressed (10, 24).
[0006] At the date there are no reports describing a successful reverse genetics system on ISAV. A relevant difficulty in generating a reverse genetics system is having the defined promoter for RNA polymerase I, which has not yet been described for Atlantic salmon. The difficulty lies in that promoters for RNA Polymerase I are strictly species-specific, they do not have a clear genetic structure and are in the IGS region of rDNA, which are vast (6). Identification of the sequences corresponding to the promoter for Pol I and its enhancers is hard work, considering that the IGS in the Salmo gender varies between 15-23 kb length (5). For this reason, and in view of the need of having a promoter with RNA Pol I characteristics, here we evaluate the capacity of the 571 pb ITS-1 region (Internal Transcribed Sequences) as previously described for Salmo salar (Atlantic salmon) (25). It has been recently described in nematodes, through bioinformatics analysis, that the ITS-1 region contains transcription promoter motifs and regulator motifs in which their function are not been demonstrated yet (29). It is suggested in this study that in the ITS-1 region of the rDNA, there are motifs having promoter characteristics and transcription regulators that have been conserved for millions of year of evolution, differing between species of the same gender, although they suggest the making of in vitro transcription assays to prove it.
[0007] The present invention shows that ITS-1 region of the rDNA of Atlantic salmon shows transcription promoter activity, which has conserved for millions of years; however, to confirm this assertion in vitro transcription essays had to be made.
[0008] In Chile and all other salmon farmers, there is the urgent need of figure out virulence factors, pathogenesis mechanisms of ISA virus, and an efficient vaccine against the only member of the Isavirus gender, the implementation of a plasmidal reverse genetics system allowing to generate recombinant ISA virus (ISAVr) becomes a necessity. With this goal, the challenge of developing a reverse genetics system for ISAV based on plasmids and using innovative elements, such as the use of salmon's ITS-1 region which has never been described as a promoter element. A choice that turned out to be key for the success of the systems that will be described below.
DESCRIPTION OF THE INVENTION
[0009] Although this methodology has been initially developed to obtain viral particles of the ISA virus, it has been also confirmed that in other species of upper vertebrates this expression system is successful for the production of RNA molecules without any additional nucleotides on their ends, which significantly broadens the usefulness of this technique. This way, with this expression system it is possible to obtain any desired protein or RNA, in a countless different cell types. An example thereof is this system's capacity to transcribe viral RNA at 12 hpt in a human KEK 293 cell line as well as in a ST swine cell line, incubated at 37° C. (98.6° F.).
[0010] Therefore, the present invention seeks to solve the technical problem of providing a molecular genetics system allowing to obtain functional viral particles from ns-RNA. Other purpose of this invention is to provide a method for expressing autogenic or exogenic proteins to the viral particle used, as well as to express nucleic acids of the interference ARN-type.
DETAILED DESCRIPTION OF THE INVENTION
Cell Lines Used
[0011] ASK cells (www.atcc.org, CRL 2747), derived from Atlantic salmon kidney, were cultured in Leibovitz medium (L-15, Hyclone), supplemented with 50 μg/mL gentamicin), 10% bovine serum (SFB, Corning cellgro®, Mediatech), 6 mM L-glutamine (Corning cellgro®, Mediatech) and 40 μM β-mercaptoethanol (Gibco®, Life Technologies). RTG-2 cells (http://www.phe-culturecollections.org.uk, ECACC 90102529), derived from rainbow trout gonad tissue, were cultured in a minimum essential medium (MEM, Hyclone) supplemented with 50 μg/mL gentamicin, 10% SFB (Corning cellgro®, Mediatech), 10 mM L-glutamine (Corning cellgro®, Mediatech), 1% non-essential amino acids (Hyclone) and 10 mM HEPES (Hyclone). CSE-119 cells, derived from Coho salmon embryo (http://www.phe-culturecollections.org.uk, ECACC 95122019) were cultured in a minimum essential medium (MEM, Hyclone) supplemented with 50 pg/mL gentamicin, 10% SFB (Corning cellgro®, Mediatech), 2 mM L-glutamine (Corning cellgro®, Mediatech), 1% non-essential amino acids (Hyclone). The cell lines were raised at 60.8° F., without CO2, except for CSE-119.
[0012] HEK293 cells (ATCC CRL 1573), human embryonic kidney cells, were cultured in Eagle's Minimum Essential Medium (EMEM, Hyclone), supplemented with 50 μg/mL gentamicin, 10% FBS (Corning cellgro®, Mediatech), 10 mM L-glutamine (Corning cellgro®, Mediatech), 1% non-essential amino acids (Hyclone) and 10 mM HEPES (Hyclone). ST cells (www.atcc.org, CRL 1746) derived from swine testicles, were cultured in Eagle's Minimum Essential medium (EMEM, Hyclone) supplemented with 50 μg/mL gentamicin), 10% FBS (Corning cellgro®, Mediatech), 10 mM L-glutamine (Corning cellgro®, Mediatech), 1% non-essential amino acids (Hyclone) and 10 mM HEPES (Hyclone).
Purification of ISAV Viral Particles
[0013] Virus purification was performed from 40 mL of ASK cell supernatant infected with the ISAV901_09 strain. After 14 post infection days, the cell supernatant was taken and clarified at 1000×g for 20 minutes at 39.2° F. The supernatant was then ultracentrifuged at 133,200×g for 2 hours at 4° C. (39.2° F.) and the pellet obtained was suspended in 100 μL TNE buffer overnight, at 4° C. (39.2° F.). Then, the suspension was loaded into 4 mL of a 20% w/v sucrose mattress in TNE buffer, and was ultracentrifuged at 124,200×g for 2 hours at 4° C. (39.2° F.), and, finally, the resulting pellet was re-suspended in 50 μL of TNE buffer.
Viral RNA Extraction
[0014] Viral RNA extraction (vRNA) was performed from 50 μL of purified ISAV901_09 virus, using the commercial E.Z.N.A kit. Total RNA Kit II (Omega, Bio-Tek, Inc.), according to manufacturer's instructions. The purified RNA was then quantified by measuring absorbance at 260 nm through the Nanoquant Infinite M200 pro (TECAN, Austria) equipment, and a vRNA concentration of 2.7 μg/μL was obtained. The vRNA was stored at −80° C. (−112° F.), until its use.
Amplification of the Complete 8 IASV 901_09 Genomic Segments, Bioinformatics Analysis and Primer Design.
[0015] The sequences including the non-coding 5′ and 3′ UTR ends of the eight genomic segments of the publications by Fourrier et al., Kulshreshtha et al., and Merour et al., (11, 17, 20), were collected. These sequences correspond to two Scottish isolates (390/98 and 982/08), one Norwegian isolate (Glesvaer/2/90), two Canadian isolates (NBISA01 and RPC NB 98-049) and a Chilean one (ADL-PM 3205 ISAV). Multiple alignment was performed using the ClustalW2 program. Based on the analysis of the alignments, the universal primers were designed to amplify the 8 complete segments, including the 5′ and 3′ UTR regions of any ISAV strain (Table I).
RT-PCR
[0016] The viral RNA of ISAV901_09 (7) was obtained by extraction from purified virus; the cDNA of the eight genomic segments was obtained via RT-PCR. To this effect, the SuperScript™ One-Step RT-PCR System with Taq Platinum DNA Polymerase kit (Invitrogen) was used following manufacturer's instructions. In order to obtain the cDNA of each segment in the RT-PCR reaction, the primer F (forward) (10 μM) and the appropriate R primer (reverse) (Table I) and 50 ng viral RNA, were used.
[0000]
TABLE 1
Primers for amplifying the 8 complete ISAV
segments
Primer
F (forward) 5′ to 3′ primer
R (reverse) 5′ to 3′ primer
1a
AGCTAAGAATGGACTTTATATCAGAAAAC
AACCTTCGAAGCCAAACAGATAG
ACG
1b
CAATATCAAGTCCGTTCGACGTGG
AGTAAAAAATGGACATTTTATTGATTAAAAGTATC
GTC
2
AGCAAAGAACGCTCTTTAATAACC
AGTAAAAAATGCTCTTTTACTTATTAAAAAT
3
AGCAAAGATTGCTCAAATCCC
AGTTAAAATTGCTCTTTTCTTTATTTG
4
AGCTAAGATTGGCTGTTTCAAGA
AGTAAAAATTGGCTTTTTGGAAAA
5
AGTTAAAGATGGCTTTTCTAACAATTTT
AGTAAAAATTGGCTATTTATACAATTAATAATG
6
AGCAAAGATGGCACGATTCA
AGTAAAAAATGCACTTTTCTGTAAACG
7
AGCTAAGATTCTCCTTCTACAATGGA
AGTAAAAATTCTCCTTTTCGTTTTAAA
8
AGCAAAGATTGGCTATCTACCA
AGTAAAAAAAGGCTTTTTATCTTTTG
Sequencing
[0017] The cDNAs of the ISAV genomic segments were cloned in the pGEMT-easy vector (Promega), following manufacturer's instructions. Three clones of each plasmid were sequenced using universal primers for promoter T7 and SP6, in addition to internal primers for each segment, as described in Cottet et al (7).
[0018] The sequencing results were analyzed using the BioEdit Sequence Alignment Editor 7.1.3 program, and to confirm the identity of the sequences, a local alignment was made using the BLAST server. In addition, a multiple alignment, using the CLUSTALW2 server between the sequences obtained from the 3′ and 5′ UTR ends of all the ISAV901_09 segments, was made. Once the complete sequences of the 8 segments of ISAV901_09 (with the 3′ and 5′ UTR ends) were obtained, they were used to synthesize the ISAV901_09 genome (Genscript Co. USA), incorporating into its ends the cleavage sites for the Sapl enzyme, and, thus, avoiding errors in the subsequent cloning in the pSS-URG vector.
[0000] Design of the Universal pSS-URG Vector Plasmid
[0019] In order to have a plasmid allowing for the transcription of the ISAV vRNA, a cassette that was synthesized using advances in synthetic biology (Genscript Co.), and incorporated into the pUC57 plasmid, was designed. The new vector built was called pSS-URG (plasmid for Salmo Salar Universal Reverse Genetic). FIG. 1 c shows the scheme of all of the elements required for a correct transcription of vRNAs. Arranged from left to right, it follows that: as a promoter, ITS-1 region of Salmo salar; the sequence of hammerhead rybozime; rybozime of the hepatitis Delta virus (δ); between the sequences of the two ribosomes are the cut sites for the Sap I distant cut enzyme (New England Biolabs), and, finally, the rabbit β-globin transcription terminator. This innovative design allows to insert any ISAV genomic segment, or any other nucleotidic sequence, without incorporating other sequences at vRNA's both ends. Then, each one of the 8 cDNAs of the complete ISAV segments were cloned in the Pss-URG plasmid. This way, a collection of plasmids called pSS-URG/1, pSS-URG/2, pSS-URG/3, pSS-URG/4, pSS-URG/5, pSS-URG/6, pSS-URG/7 and pSS-URG/8, is obtained ( FIG. 1 e ).
[0000] pSS-UGR/S6-NotI-HPR and pSS-UGR/S6-EGFP-HPR Vector
[0020] A construct was designed based on the pSS-URG vector having the complete sequence (including the 3′ and 5′ UTR ends) in antisense and inverted from segment 6 of ISAV 901_09. As a marker, the vector has additions, in frame, within the HPR region of segment 6, exactly nine nucleotides containing the restriction site for the NotI enzyme nt 1015 5′-gtagca[GCGGCCGCA]acatct-3′nt 1.036 ( FIG. 2 ). The designed vector, called pSS-UGR/S6-NotI-HPR, was synthesized at GenScript Co., using pUC57 as basis. In order to generate the pSS-URG/S6-EGFP-HPR vector, the EGFP coding sequence was cloned into the pSS-UGR/S6-NotI-HPR vector using Not I restriction site of the HPR region ( FIG. 2 ).
Vectors to Express PB2, PB1, PA and NP Proteins of ISAV901_09
[0021] From the ORFs of segments 1, 2, 3, and 4 of ISA virus 901_09 encoding for PB2, PB1, PA and NP, respectively, (ID N° 7, 8, 9, 10) and which are cloned in the pGemT-easy vector (7), high fidelity PCR with Pfx Platinum (Invitrogen) was performed. The primers used to amplify each one of the gens are shown in Table 2, which include cutting sites for Ncol, Smal and Xhol enzymes (New England biolabs). Cloning ORFs of PB2 and PA was made with Ncol and Xhol restriction enzymes, cloning of the ORF from PB1 was made with Smal and Xhol restriction enzymes, and that of the ORF encoding for NP was with Mlul and Xbal restriction enzymes. For the expression of PB2, PB1 and PA, the ORFs of segments 1, 2, and 3 were cloned in the pTriex3 vector (Novagen). On the other hand, for the expression of the NP protein, the ORF of segment 3 was cloned in the pCI-neo vector (Promega).
[0000] TABLE 2 Primers to amplify the PB2, PB1, PA and NP ORF of ISAV901_09 for cloning CMV vectors. ORF 5′ to 3′ Primer F 5′ to 3′ primer R PB2 NcoI - ATGCC ATGGACTTTATATCAGAA XhoI-CCG CTCGAG AACACCATATTCATC AACACGATCAGCG CATAGG PB1 SmaI-TCC CCCGGG AAACTCTAGTAGGTG XhoI-CCG CTCGAG AACACGCTTTTTCTTCTT AATCAC NP MluI-CG ACGCGT CATGGCCGATAAAGGT XbaI-CGC TCTAGA TCAAATGTCAGTGTCTTC ATGAC CTC PA NcoI- CATGCC ATGGATAACCTCCGTGAA XhoI-CCG CTCGAG TTGGGTACTGACTGCAA TGCATAAACC TTTTC
Ex Vivo Transcription Trial, ASK Cell Transfection Kinetics with pSS-URG/Seg6-NotI Vector
[0022] To test the functionality of the pSS-URG base vector, ASK cells were seeded at a density of 2.5×10 4 cell/cm 2 per well in a 24-well plate (SPL) in Leibovitz Medium (L-15, Hyclone), supplemented with gentamicin (50 μg/mL) and 10% fetal bovine serum (SFB, Hyclone) being cultured at 18° C. (64.4° F.), until reaching 80% confluence. The cells were transfected with the pSS-URG/S6-NotI-HPR vector using Fugene 6 (Promega) at a 1:6 ratio, following manufacturer's specifications. The cells were incubated at 16° C. (60.8° F.) for 3 hours, the mixture being then removed and the cells washed 2 twice with PBS, starting with transfection kinetics that is at 0, 3, 6, 9, 12 and 15 hours. From each well, at each point of the kinetics, total RNA was extracted from the cells using E.Z.N.A. Total RNA Kit II (Omega, Bio-Tek), DNA was eliminated by using RQ-DNase treatment (promega). The RNA obtained was subjected to RT-PCR using primers for the NotI restriction site and the 5′UTR end of viral segment 6 (Table 3).
[0000]
TABLE 3
Primers to amplify vRNA of S6-NotI
Primer
5′ to 3 sequences′
F S6-NotI
GTAGCAGCGGCCGCA
R S6-5′UTR
AGTAAAAAATGCACTTTTCTGAAACG
[0023] cDNA was obtained through reverse transcription (RT) using the M-MuLV Reverse Transcriptase enzyme (Moloney Murine Leukemia Virus Reverse Transcriptase, 200U/μL New England BioLabs). The reverse transcription mixture was made at a final 25 μL volume, in accordance with manufacturer's specifications. cDNA was then used to carry out a PCR reaction with DNA polymerase Paq5000 (Agilent Technologies). PCR products were visualized by electrophoresis at 90 volts for 1 hour on a 2% ethidium bromide-stained (10 mg/mL) agarose gel ( FIG. 3 ).
Generation of Recombinant ISAV (ISAVr) Through Plasmid-Based Reverse Genetics System
[0024] ASK cells were seeded at a density of 2.5×10 4 cell/cm 2 on Nunc™ Lab-Tek™ II Chamber Slide™ System plates, and then incubated for 72 hours at 18° C. (64.4° F.). The cells were transfected with Fugene 6 (Promega) 1:6, in accordance with manufacturer's specifications. As for the generation of ISAVr 901 _ 09 , a total of 250 ng of a mixture of vectors pTriex-3-PB2, pTriex-3-PB1, pTriex-3-PA and pCI-neo-NP and 1 μg of the total eight pSS-URG (pSS-URG/1-8) vectors. Recovery of the rISAVS6-NotI-HPR and rISAVS6-EGFP-HPR viruses was performed by replacing pSS-URG/6 with pSS-UGR/S6-NotI-HPR and pSS-URG/S6-EGFP-HPR, respectively. The cells were then incubated with 1 mL of L-15 medium, for 7 days at 16° C. (60.8° F.) ( FIG. 4 ).
[0000] Infection of ASK Cells with ISAVr S6-EGFP-HPR
[0025] ASK cells were seeded at a density of 2.5×10 4 cell/cm 2 per well, in 8-well Nunc™ Lab-Tek™ II Chamber Slide™ System plates, and were cultured at 16° C. (60.8° F.), until reaching 90% confluency. Then, the cells were washed with PBS twice, and blind passages were made with 100 μL of a 1:10 dilution of the supernatant either from passage 0 (P0) at 7 days post-transfection or from the different passages at 7 days post infection of ISAVrS6-EGFP-HPR in L-15 medium without SFB with gentamicin (50 μg/mL). The cells were incubated for 4 hours at 16° C. (60.8° F.), then washed twice with PBS and 500 μL of L-15 medium was added with 10% SFB and gentamicin (50 μg/mL), being then incubated for 7 days at 16° C. (60.8° F.). Each viral passage was obtained with this procedure every 7 days up to the fourth ISAVr S6-EGFP-HPR passage, in addition to P0. The supernatant of each passage was stored at −20° C. , until further analysis thereof ( FIG. 4 ).
ISAVr S6-EGFP-HPR Detection
[0026] RNA extraction, RT-PCR and qRT-PCR in real time:
[0027] To detect ISAVr S6-EGFP-HPR, a total RNA of 350 μL was extracted from the ASK cells' supernatant as transfected with the 12 plasmids at 7 post-transfection days (ISAVr S6-EGFP-HPRN ) or supernatants from the 1st to 4 th blind passages, with RNAv extracted from RNAv of segment 6, EGFP and Segment 6-EGFP being detected through RT-PCR.
[0028] Prior to the RT-PCR reaction, the RNA was treated with RNase-free DNase (Promega). For the reverse transcription reaction (RT), F-UTR-S6 primers (Table 1), F-S6 primers (Table 3), or EGFP primers (Table 4) were used, using the M-MLV RT enzyme (200 U/μL Promega), in accordance with manufacturer's specifications.
[0000]
TABLE 4
Primers for the detection of vRNA from
S6-EGFP-HPR
Pri-
mer
5′ to 3′ primer F
5′ to 3′ primer R
S6
TGAGGGAGGTAGCATTGCAT
AAGCAACAGACAGGCTCGAT
EGFP
CTGGAAGTTCATCTGCACCAC
TGCTCAGGTAGTGGTTGTC
S8
GAAGAGTCAGGATGCCAAGACG
GAAGTCGATGAACTGCAGCGA
[0029] For PCR, the GoTaq® Green Master Mix kit (Promega) and Forward (S6 or EGFP) and Reverse (S6 or EGFP) primers were used. The thermal program used was: 95° C. for 2 minutes, 35 95° C. cycles for 30 seconds, 59,1 ° C. for EGFP, or 54° C. for S6 or S6-EGFP, 30 seconds, 72° C. for 30 seconds, and a final extension of 72° C. for 5 minutes. In all of the cases, re-amplification of the PCR products was carried out, using the same primers. The products of the PCR re-amplification were visualized via electrophoresis on 1% (w/v) agarose gel, run at 90 V for 45 minutes, and stained with ethidium bromide (10 mg/mL).
[0030] In order to detect the number of copies of the vRNA, a qRT-PCR was carried out in real time using the absolute method as described by Munir and Kibenge (22), a standard curve being made from the pSS-URG/S8 plasmid. The RT-PCR analysis in real time was carried out on the Eco Real-Time PCR System equipment (Illumina), using the SensiMix™ SYBR® Hi-ROX Kit (Bioline), following manufacturer's instructions, using the F-S8 and R-S8 primers (Table 4). The thermal profile used to amplify the region of segment 8 was 1 initial denaturation cycle of 10 minutes a 95° C., followed by 40 amplification cycles (15 seconds at 95° C., 15 seconds at 60° C., and 15 seconds at 72° C.). Following the amplification cycles, a dissociation cycle (30 seconds at 95° C., 30 seconds at 55° C., and 30 seconds at 95° C., was carried out. This procedure was performed for passage 4 of the recombinant virus. The results obtained were analyzed on EcoStudy software.
Confocal Microscopy
[0031] On the 7th post-infection day, ASK cells infested with rISAVS6-EGFP-HPR in each passage of the recombinant virus were analyzed via confocal microscopy, using the procedure as described by Rivas-Aravena et al. (45). The fixed cells were observed using a LSM 510 confocal microscope (Zeiss), utilizing the LSM image Browser software to detect rISAVS6-EGFP-HPR by visualizing EGFP fluorescence. In addition, rISAV was detected using anti-HE monoclonal antibody (BiosChile), as was already described (45).
Tagging by Lysis Plate Trial
[0032] ASK cells were seeded at a density of 2.5×10 4 cell/cm 2 per well of a 12-well plate (SPL) and were incubated at 16° C. until reaching 100% confluency. The ISAVr S6-EGFP-HPR variant of Passage 4 was tagged. The procedure was performed as described by Castillo-Cerda et al (35).
ISAVr S6-EGFP-HPR Fluorescence Quantification Trial
[0033] ASK cells were seeded at a density of 2.5×10 4 cell/cm 2 per well, in a 48-well plate (SPL), and were incubated at 16° C. until reaching 100% confluency. Passage 4 of ISAVr S6-EGFP-HPR was tagged. To this effect, serial dilutions of each viral inoculum were performed using a 10-dilution factor, from 10 −1 to 10 −6 in L-15 medium, without FBS. The culture medium was then removed and 400 μL of viral inoculum was added to each well, and it was incubated at 16° C. for 4 hours to allow virus absorption. Subsequently, the inoculum was removed from each well, the cells were washed twice with PBS and, then, the L-15 medium was added, being supplemented with 10% SFB, 6mM L-glutamine (Corning cellgro®, Mediatech), 40 μM β-mercaptoethanol (Gibco®, Life Technologies), 50 μg/ml gentamicin. The plates were incubated for 7 days at 16° C. At the end of the infection, the supernatants from each well were analyzed, fluorescence being quantified using the Nanoquant Infinite M200 pro equipment (TECAN, Austria), exciting at 485 nm, and capturing the emission at 535 nm. These supernatants were also used for extracting total RNA and subsequent qRT-PCR, in real-time, to quantify the RNAv in ISAV segment 8, and for determining, this way, the number of copies of the cell culture from segment 8, as described above.
[0000] Infection Kinetics of ISAV901_09, ISAVr 901 _ 09 , ISAVr S6/EGFP-HPR
[0034] Infections of ASK cells were carried out with the fourth passage of ISAVr S6/EGFP-HPR , using the fourth passage of ISAVr 901 _ 09 as control, in addition to wild ISAV901_09. For each virus isolate, an infection was carried out with a MOI of 0.01. The infection kinetics was carried out by collecting samples at 0, 2, 4 and 7 days after the infection, then a RNA extraction, DNase treatment, and then a real-time qRT-PCR were carried out, to quantify RNAv of ISAV segment 8 of each cell culture supernatant (22).
Visualization of Particles
[0035] The ASK cells were seeded as indicated above and cultured at 16° C. until reaching 90% confluence. Cells were then infected with 400 μL of a 1:10 dilution of ISAVr S6/EGFP-HPR virus in its 4th passage, or the 4th passage of rISAV 901 _ 09 or wild ISAV901_09 as control. Four days after infection, the cells were fixed with 2.5% glutaraldehyde in cacodylate buffer 0.1 M at pH 7.2 for 6 hours at room temperature, and then washed with sodium cacodylate buffer 0.1 M at pH 7.2 for 18 hours at 4° C. The samples were then fixed with 1% aqueous osmium tetroxide for 90 minutes, and then washed with distilled water and stained with an aqueous solution of 1% uranyl acetate for 60 minutes. Samples were then dehydrated with washes of 20 minutes each time with a series of buffers containing acetone 50, 70, 2×95 and 3×100%. Samples were finally embedded in epon resin/acetone at 1:1 ratio overnight, and then embedded in pure epon resin which was polymerized at 60° C. for 24 hours. Thin sections (60-70 nm) were obtained in ultramicrotome Sorvall MT-5000, and then mounted on copper grids, and then stained with 4% uranyl acetate in methanol for 2 min, and then citrate for 5 min. The samples were observed with a 12 to 80 kV electron microscope Philips Tecnai ( FIG. 6 ).
DESCRIPTION OF THE FIGURES
[0036] FIG. 1 : Obtaining the plasmids to allow transcription of the 8 RNAv of ISAV901_09: (1) pSS-URG plasmids and the plasmid containing each of the ISAV genome segments are digested with the Sapl restriction enzyme. The digestion products are visualized on a 1% agarose gel, and then purified. (2) The digested product corresponding to the ISAV genome segment and the linear pSS-URG plasmid are ligated with T4 ligase, and then this ligation is used to transform chemo-competent bacteria. (3) From the clones containing the expected recombinant plasmids, purification is carried out to confirm the correct insertion of the genome segment by sequencing.
[0037] FIG. 2 : Schematic design of pSS-URG, pSS-URG/S6-NotI and pSS-URG/S6-EGFP-HPR cassettes. The universal vector contains the sequence of: promoter of S. salar (SS prom); hammerhead ribozyme (HH rib); hepatitis virus ribozyme δ(HDV rib); rabbit β-globin transcription terminator (Term). pSS-URG/S6-Not and pSS-URG/S6-EGFP-HPR plasmids contain the cDNA of antisense and inverted segment 6, which includes 5′ and 3′ UTRs and their modifications; NotI restriction site or the EGFP coding sequence.
[0038] FIG. 3 : RT-PCR of the 6-NotI-HPR segment from ASK salmon cells transfected with pSS-URG/S6-Not-HPR plasmids. Agarose gel electrophoresis of RT-PCR products of segment 6 at selected post transfection times. ASK cells were transfected using Fugene 6 (Promega), the plasmid used was pSS-URG/segment 6.
[0039] FIG. 4 : Reverse genetics to obtain recombinant ISA virus: ASK cells are transfected with 8 pSS-URG/S1-8 plasmids, which allow transcription of the 8 vRNA (ISAV genome), together with 4 plasmids that allow expression of the proteins that form the cRNP (PB2, PB1, PA and NP). Co-transfection of these 12 plasmids in the same cell to allow the formation of the 8 cRNP in the nucleus, which are the minimum unit required to form an ISAV viral particle. These cRNPs allow transcription and replication of the vRNA, allowing synthesis of all proteins that form the virus and the generation of new cRNPs, thus forming recombinant viral particles.
[0040] FIG. 5 : RT-PCR of 6-NotI-HPR segment from ST swine cells (a) and HEK-293 human cells (b), both transfected with pSS-URG/S6-NotI-HPR plasmid using Fugene 6 (Promega). Agarose gel electrophoresis of RT-PCR products of segment 6 at selected post transfection times.
[0041] FIG. 6 : Electron Microscopy Analysis of recombinant ISAV from sections of infected ASK cells. Cytoplasmic membrane with ISAV particles budding from infections with: (A) WT ISAV 901_09, (B) rISAVS6-EGFP-HPR and (C) rISAV 901_09. (D) Endosomal section showing rISAV 901_09 particles inside endosomes, which correspond to the initial steps of the fusion of viral and endosomal membranes. Bar: 200 nm.
EXAMPLES
ISAV 901_09 Strain Genome Adapted to Cell Culture
[0042] The complete genome of a virus isolate adapted to cell culture, such as ISAV 901_09 (HPR 1c), was sequenced.
[0043] Alignments between the noncoding regions (UTR) of the 5′ and 3′ ends of complete sequences of the six ISAV isolates, two Scots (390/98 and 982/08), one Norwegian (Glesvr/2/90), two Canadian (NBISA01 and RPC NB 98-049), and one Chilean (ADL-PM 3205 ISAV) have high conservation at the ends of each viral genome segment, allowing to design universal primers described in Table I. The primers were used to amplify the genome of the Chilean ISAV 901_09 strain. The result of sequencing the eight viral genome segments is shown in Table IV. The sizes of the eight viral segments range from 2267 bp to 906 bp for segments 1 and 8, respectively.
[0044] The sequence of the 3′UTR regions ranged from 7 nucleotides in segment 6 to 48 nucleotides in segment 3, and there were no differences in the size of each 3′UTR end previously described for the 6 genomes analyzed, except for the addition of a nucleotide at the 3′UTR end of segment 7. The sequences of the 5′UTR ends of ISAV 901_09 range from 67 nucleotides in segment 4 to 147 nucleotides in segment 3. The alignment of the UTR regions also indicates that ISAV 901_09 has a high similarity with the ISAV Glesvr/2/90 strain (between 97% and 98% identity).
Universal Vector Design for ISAV Reverse Genetics
[0045] In order to achieve a vector which expresses segments of full-length viral RNA without additional nucleotides, taking advantage of advances in synthetic biology, an innovative design was made integrating elements previously used in reverse genetics of RNA viruses, such as Hammerhead ribozymes and delta (δ) hepatitis virus, together with genome elements of the Salmo salar species. The designed vector was called pSS-URG (plasmid for Salmo salar Universal Reverse Genetic). The correctly connected components contained by the vector and ordered from left to right are: As a promoter ITS-1 region of Salmo salar, a sequence of Hammerhead ribozyme, the ribozyme of delta (δ) hepatitis virus, and the sequences of the two ribozymes incorporate two cutting sites for Sap I enzyme (New England Biolabs), and finally incorporated as transcription terminator is rabbit beta globin terminator ( FIG. 2 ). This vector would allow cloning, without incorporating additional sequences, any viral segment, through the use of a distant cut enzyme, such as Sap I. Thus, this study presents a vector to be the base of the reverse genetics system for the ISA virus.
[0046] Once the pSS-URG plasmid is synthesized, subcloning of the eight genome segments of ISAV was achieved from synthetic genomes using distant cut enzyme Sap I (Data not shown). In addition to cloning the eight viral segments, as a genetic marker and in order to prove that generated viruses are recombinant agents and do not correspond to a contamination of the procedure, two genetic elements were inserted in the HPR area of the universal vector containing segment 6. The first genetic variant corresponds to the insertion in the HPR area of a sequence of nine nucleotides with the cutting site for the NotI enzyme, calling this new vector pSS-URG/S6-NotI-HPR. A second genetic variant corresponds to the product of cloning the sequence which codes for EGFP using previously created NotI site, thus the new vector called pSS-URG/S6-EGFP-HPR is obtained.
[0000] Analysis of Functionality for pSS-URG Vector by Ex Vivo Transcription Trial
[0047] To determine whether all the elements included in the vector allow the expression of viral RNA in salmon cells, and due to the uncertainty of functionality of the promoter suggested in ITS-1 region of Salmo salar, ASK cells were transfected with pSS-URG/S6-NotI-HPR plasmid in an ex vivo transcription trial. To determine the existence of a transcription process, the functionality analysis was made by detecting the RNAV at times 0, 3, 6, 9, 12 and 15 after transfection (hpt) through RT-PCR. The reverse transcription reaction was made using a single first complementary to the Not I restriction site. Surprisingly, the analysis result can display a PCR product from three hpt, which increases in intensity until 15 hpt ( FIG. 3 ). This result would indicate that from transfected pSS-URG/S6-NotI-HPR plasmid, the cell is generating an RNA having the NotI restriction site, and therefore ITS-1 region of Salmo salar corresponds to a promoter element. To prove the generation of a viral RNA without additional nucleotides, a RT-PCR was carried out with specific primers for each ribozyme, the results showed that it was not possible to obtain an amplification product with primers that recognize sequences of ribozymes in any point of kinetics, indicating that generated RNA has no additional regions, such as, for example, ribozymes (data not shown).
[0048] These results suggest the use of the ITS-1 region and the inclusion in pSS-URG vector to express any type of RNA inside the cells. For example, RNA can be expressed as interfering RNA, silencing RNA or also micro RNAs.
Obtaining Recombinant ISA Virus (ISAVr)
[0049] As it has been reported for Influenza virus, the functional minimum unit of the virus corresponds to the ribonucleoprotein (RNP) complex, which consists of viral RNA that is bound by multiple copies of NP and by the viral polymerase including PB1, PB2 and PA subunits. In order to form the RNP complexes in salmon cells, ORFs of segments 1 to 4 of ISAV901_09 were cloned into expression vectors commanded by the Cytomegalovirus promoter. Thus, using the pTriEx-3 vector (Novagen), ORFs of segments 1, 2 and 4 were cloned, obtaining pTRiex3-PB2, pTRiex3-PB1, pTRiex3-PA vectors. Besides, using the pCI-neo vector (Promega), segment 3 was cloned generating pCI-neo-NP vector (Data not shown). Transfection of these vectors into salmon cells allows expression of recombinant proteins PB2, PB1, PA and NP, respectively.
Generation of ISAVr S6-NotI-HPR
[0050] For the generation of ISAVr S6-NotI-HPR , ASK cells were cotransfected with twelve plasmids, four of which correspond to expression vectors pTRiex 3-PB2, pTRiex 3-PB1, pTRiex 3-PA and pCI-neo-NP, and the remaining eight correspond to plasm ids for pSS-URG reverse genetics with each of the eight genome segments of ISAV901_09 as DNA, replacing native segment 6 by Seg6-NotI-HPR. In order to amplify and determine the presence of recombinant virus, after transfection of cells, two blind passages were made in ASK cells infecting with the supernatants obtained from the previous transfections. On the one hand, the presence of RNAV of segment 6 (NotI/HPR) was detected, through RT-PCR, obtaining a product of an expected 306 bp size, both in the RNA extracted from the transfection supernatant and from the two subsequent passages, which suggests the presence of infectious viruses. The second passage supernatant was used to infect a greater amount of ASK cells. From the infected cells, which showed an obvious cytopathic effect (data not shown), the recombinant virus was visualized by transmission electron microscopy. FIG. 6 shows spherical particles similar to virus with diameters near 100 nm, which suggests that these correspond to the recombinant viruses. Therefore, it was possible to detect a recombinant ISAVr S6-notI-HPR virus in infected cells, with replicative activity and reproducible cytopathic effect in passages subsequent to their generation.
Generation of ISAVr S6-EGFP-HPR
[0051] In order to generate recombinant ISA virus containing a reporter gene, such as EGFP, in order to facilitate ex vivo monitoring and discard that results are artifactual results or contamination, ASK cells were co-transfected with twelve plasmids simultaneously: four of them correspond to expression vectors pTRiex3-PB2, pTRiex3-PB1, pTRiex3-PA and pCl-neo-NP; the remaining eight plasmids correspond to vectors pSS-URG/1, pSS-URG/2, pSS-URG/3, pSS-URG/4 , pSS-URG/5 , pSS-URG/7 and pSS-URG/8; also incorporating segment 6 with vector pSS-URG/S6-EGFP-HPR; the virus which contains EGFP in the HPR area of the protein is called ISAVr S6-EGFP-HPR .
[0052] To determine whether recombinant viral particles were generated after transfection, the culture supernatant (passage 0 , P 0 ) was analyzed 7 days after transfection (dpt). For this purpose, it was initially detected by RT-PCR RNAv of Segment 6 , as well as the EGFP coding sequence in a second PCR product, and finally an area containing both part of Segment 6 and the EGFP. The results showed that RT-PCR products for Segment 6 have a different migration distance of the PCR products for the native virus (−300 bp) and the recombinant virus having EGFP in the HE protein (1,000 bp). The RT-PCR of the EGFP coding sequence has a ˜500 bp product, which is not observed in the native virus analyzed. For RT-PCR of S6-EGFP, an amplification product of −800 bp was obtained for the recombinant virus as expected.
Infectivity of ISAVr S6-EGFP-HPR in ASK Cells
[0053] To determine whether the supernatant of ASK cells transfected with twelve plasmids indeed contains the viral variant ISAVr S6-EGFP-HPR with the characteristics of an infectious agent, EGFP fluorescence was used as a reporter. The ASK cells infected with the supernatant that would contain the first progeny ISAVr S6-EGFP-HPR were analyzed under confocal microscope 7 days after infection. The results show that it is possible to visualize cells emitting green fluorescence attributable to EGFP, corresponding to the first passage of the ISAVr S6-EGFP-HPR virus. Distribution of the EGFP mark is found mainly in the cytoplasm and towards the plasma membrane, fluorescence being not observed in the cell nucleus. To confirm that the supernatant of transfected cells (passage 0 ) contains the ISAVr S6-EGFP-HPR virus with lytic capacity, a lysis plaque trial was carried out on ASK cells. The result of the lysis plaque trial showed that the recombinant virus has the ability to generate lysis plaques like the wild virus, obtaining a virus titre in the order of 1×10 4 PFU/m L.
[0000] Stability of lSAVr S6-EGFP-HPR
[0054] Subsequently, the ability of this recombinant virus to maintain infectiousness and fluorescence was assessed in cell culture. Four blind passages of infection in ASK cells were carried out with 7-day gaps. Then, in each supernatant of the recombinant virus passages, a RT-PCR was carried out to detect RNAv both of Segment 6 and of the coding sequence for EGFP, and a region of the EGFP-S6 hybrid sequence. The result made possible to visualize a PCR product of 500 bp EGFP and EGFP-S6 hybrid sequences of 800 bp, indicating the presence of segment 6 containing the EGFP gene in all supernatants analyzed. The PCR product of segment 6 shows a 300 bp product in the supernatant of infected ASK cells with ISAV901_09 wild virus, as expected, in contrast to the 1,000 bp of the PCR product obtained in each of the four passages of ISAVr S6-EGFP-HPR virus, whose larger size is the result of having incorporated the EGFP gene in segment 6 .
[0055] To determine that each of the four passages not only had a virus with infectivity, but also was capable of fluorescing, indicating the correct folding of HE with EGFP in the HPR area, an analysis was carried out by confocal microscopy in infected ASK cells. Confocal microscopy showed cells that emit green fluorescence in all passages analyzed, increasing in each passage the abundance of fluorescent cells. These results suggest that the region of the HE protein elected to incorporate EGFP is not affected by the incorporation of this ORF, thus allowing the generation of a chimeric recombinant ISA virus capable of replicating, infecting and spreading in multiple passages without losing the ability to fluoresce. Titration of the fourth blind passage made to ISAVr S6-EGFP-HPR virus by qRT-PCR in real time resulted in a titre of 3.63×10 6 copies Seg 8/mL and a value of 6.5×10 5 PFU/mL obtained by lysis plaque trial, showing a lysis plaque size similar to that observed after conducting plaque trial on ISAV901_09 wild virus.
[0000] Infectivity of ISAVr S6-EGFP-HPR in salmonid cell lines
[0056] In order to determine whether by incorporating a sequence in the HPR area of the ISAVrs6-EGFP-HPR virus, this acquires the ability to infect other salmonid species or lose infectivity in permissive cells (ASK cells), an infection kinetics was carried out in RTG-2, CSE-119 and ASK cells. The ex vivo trial was conducted for 7 days using the fourth passage of the fluorescent recombinant virus and compared to the ISAV901_09 wild virus, and the fourth passage of a wild recombinant virus generated for this trial rISAV 901 _ 9 (MOI of 0.01). The analysis at 0, 2, 4 and 7 dpi by qRT-PCR quantifying the number of copies of segment 8 in each supernatant showed that none of the three viruses analyzed had the ability to replicate in RTG-2 cells or in CSE-119 cells.
[0057] In contrast, the infection kinetics carried out on ASK cells showed that initially the ISAV 901_09 virus has a larger number of copies than recombinant viruses, rISAV 901 and rISAV S6-EGFP-HPR . On the second day after infection, however, an increase occurs in the number of copies of the recombinant viruses, reaching titres near 1,000 segment 8/mL, with values similar to the wild virus. These results suggest that the incorporation of EGFP in the HPR area of HE protein does not alter the replicative behavior of the fluorescent recombinant virus in ASK cells, and does not extend the host range at least in the ex vivo trials in RTG-2 cells or in CSE-119 cells.
[0058] These results can lead to the conclusion that it is possible to incorporate into the pSS-URG plasmid a sequence encoding both for a viral protein and for an exogenous or chimeric protein, thus achieving the generation of a modified or chimeric recombinant ISA virus; these modifications would not alter or affect its infectious or propagation characteristics.
[0000] Functionality of pSS-URG Plasmid in Salmon, Swine and Human Cell Lines
[0059] To determine the ability of the pSS-URG/S6-NotI-HPR vector for transcribing segment 6 as RNAv, it was transfected into ASK cells using Fugene 6 (Promega) at a 1:6 ratio and according to manufacturers' specifications. 0 hpt is considered as the time when adding the transfection mix to the cells. The initial incubation takes place for 3 hours at 16° C. F. Once the incubation time had elapsed, the transfection mix was removed and the cells were washed twice with PBS, this being a 3-hpt time. At each point of the transfection kinetics, which occurs at 0, 3, 6, 9, 12 and 15 hpt, the cells are removed for extraction of total RNA, possible contaminating DNA was removed with DNase I. With the RNA obtained, RNAv of segment 6 NotI was detected by RT-PCR using specific primers for segment 6 NotI. The analysis allows to observe a PCR product of expected 306 bps size from 3 hpt, which increases in intensity until 15 hpt ( FIG. 3 ). Therefore, it is proved that the pSS-URG plasmid is functional.
[0060] Surprisingly, the ability to transcribe the viral RNA is not restricted to salmon cells cultured at 16° C. Using the same procedure (with incubations at 37° C.), but conducted only at 12 hpt, functionality was observed in human cell line HEK 293 and swine cell line ST, incubated at 37° C. ( FIG. 5 ). This is reflected in obtaining a RT-PCR product of the expected size which allows to conclude that the vector is functional in salmon cell lines incubated at 16° C. and mammal cell lines incubated at 37° C., being this a tool that would allow the expression of any RNA in cells or tissues of vertebrate animals, whether cold-blooded or warm-blooded.
ISAVr S6-EGFP-HPR : Correlation Between the Number of Viral Copies and Measured Fluorescence
[0061] Since the ISAVr S6-EGFP-HPR virus has similar characteristics to the wild virus when infecting ASK cells, and also has the advantage of monitoring the infection by incorporating EGFP as reporter, the goal is to determine whether there is correlation between the viral load and fluorescence in the supernatant of infection caused by this recombinant virus. The analysis carried out on serial dilutions of fluorescent recombinant virus through qRT-PCR and fluorescence quantitation established that there is a direct relationship showing an increased fluorescence detected when the viral titer of the solution increases, showing a fluorescence intensity of 500 units/mL for a titer of 2×10 6 copies/mL.
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35. Castillo-Cerda M T, Cottet L, Toro-Ascuy D, Spencer E, Cortez-San Martin M. 2013. Development of plaque assay for Chilean Infectious Salmon Anaemia Virus, application for virus purification and titration in salmon ASK cells. J Fish Dis. | The present invention describes a viral RNA expression plasmid and a method for obtaining viral particles based on said plasmids comprising transfecting animal cells with an expression vector or a set of expression vectors capable of expressing a nucleoprotein and RNA-dependent polymerase RNA; and transfecting the animal cell with an expression vector or a set of expression vectors with nucleotide sequences encoding recombinant RNA molecules. | 2 |
BACKGROUND TO THE INVENTION
The present invention relates in general to the supply of a service or utility, more usually electric power or pressure medium, to a mobile appliance or machine and especially to a mobile appliance in an underground mine working.
It is known to supply electric power to an appliance, such as a locomotive or a mineral winning machine, with the aid of an electric track composed of hollow conduits or duct sections containing electric live rails and to utilize a collector or pick-up which engages through slots in the conduits to contact the live rails. Such arrangements are described, for example, in German Pat. Nos. 1515340, 2522319, 2522320 and 2522321. In order to seal off the slots in the conduits or duct sections of the prior art arrangements, elastic seals are used which engage on one another and which are pressed apart locally by the passage of the collector or pick-up. In one known form of seal, hoses are expanded by gas pressure to engage on one another. It is also known from the prior art, to introduce a protective gas under pressure in the conduits or duct sections to ensure no explosive or combustible gas can enter the duct sections. Problems can occur with the seals hitherto adopted or proposed. The hose type seal is, for example, prone to leakage of its expanding gas when it has encountered a certain amount of wear. Once the hoses begin to leak the sealing of the duct section slots fails. Also, in the prior art arrangement, the duct-sections are not reliably maintained in a sealed condition in the region of the pick-up or collector and hence protective gas must be supplied to the duct sections in relatively large quantities to supplement the loss caused by the passage of the pick-up.
A general objection of the present invention is to provide an improved construction of the aforementioned kind especially regards the sealing of the duct-section access slot.
SUMMARY OF THE INVENTION
In accordance with the invention, the slot of a duct section containing a utility or service, such as electricity or pressure medium, and through which displaceable pick-up or collector means gains access to pick up the service or utility for supply to a mobile appliance is sealed with at least one flat seal which covers over the slot and is locally deflected away from the slot by the passage of the pick-up means. It is preferable to adopt two flat seals, one engaging on the inner surface of the duct section to cover the slot and the other engaging on the outer surface of the duct section to cover the slot, thereby to cover the length and width of the slot from the inside and outside. The outer seal is particularly effective at preventing dust and extraneous matter from entering the duct section. The adoption of flat seals is considerably simpler than the prior art seals and leads to better results. The flat seals can be made of wear-resilient metal, e.g., thin resilient steel strips or synthetic plastics capable of coping with the harsh operating conditions encountered in underground mine workings. If the duct section is provided with protective gas under pressure the inner seal can be held in face-to-face contact with the inner surface of a slotted wall of the duct section by the gas pressure. However, where the strip seals are metallic and/or magnetizable, the provision of one or more magnets can hold the strip seals in the sealing position unless displaced by the pick-up means.
The pick-up means can take a variety of forms but in one preferred arrangement a body locates within the duct section and extends partly around the inner flat seal which is deflected into a cavity of the body as the pick-up means progresses along the slot of the duct section. To maintain the sealing effect locally of the body where the inner flat seal is deflected, the body itself carries additional seals which slidably engage on the inner surface of the slotted wall. The pick-up means may additionally comprise a slide member engaging in the slot and adopting a wedge-like profile to gently and progressively deflect the flat seals away from the slotted wall. The slide member is connected to the inner body and also to an outer body serving as a mounting piece located outside the duct-section. The mounting piece may also have a cavity into which the outermost flat seal is deflected and this component also may have additional seals which similarly slidably engage on the outer surface of the slotted wall to supplement the sealing effect. Means is preferably provided in the duct section to urge the inner body towards the inner surface of the duct section so its seals are pressed against this inner surface. It is also useful to provide rollers on the mounting piece and the inner body to engage on the flat seals to hold these in sealing engagement with the slotted wall in the region at the front of the pick-up means relative to its direction of movement just prior to the deflection thereof and to return the flat seals back into sealing engagement with the slotted wall on the region at the rear of the pick-up means after the deflection thereof.
A duct section and pick-up means constructed in accordance with the invention are especially useful as part of an electric supply. In this case, a number of duct sections can be joined end-to-end and they contain a common conductor, i.e., a live rail or bus bar with which electrical contacts of the pick-up means engage. The pick up means can then supply electric current to a locomotive, a winning machine or some other appliance in a mine working. To supply the protective gas to the interior of the duct sections the pick-up means can carry a conduit leading to the interiors of the duct sections. The sealing means according to the invention ensures that only slight leakage losses have to be made up by the conduit.
A duct section and pick-up means constructed in accordance with the invention can also be used to supply a pneumatic or hydraulic pressure medium to an appliance in a mine working and again the sealing means ensures only slight leakage losses. One possible use for this arrangement would be to supply water to the spray nozzles of a winning machine, such as a shearer or plough.
The invention may be understood more readily and various other features of the invention may become apparent from consideration of the following description.
BRIEF DESCRIPTION OF DRAWING
An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 is a longitudinal sectional side view of part of an electrical supply means constructed in accordance with the invention, the view being taken along the line I--I of FIG. 3;
FIG. 2 is a longitudinal sectional side view of the part of the electrical supply means depicted in FIG. 1, the view being taken along the line II--II of FIG. 4;
FIG. 3 is a cross-sectional end view of the part of the electrical supply means depicted in FIG. 1, the view being taken along the line III--III of FIG. 1;
FIG. 4 is a cross-sectional view of the part of the electrical supply means depicted in FIG. 1, the view being taken along the line IV--IV of FIG. 2; and
FIG. 5 is a perspective view of a component of the electrical supply means.
DESCRIPTION OF PREFERRED EMBODIMENT
Electrical supply means adapted for use in environments where there is a danger of explosion or fire, and especially in underground mine workings, is composed of a plurality of duct sections joined end-to-end in flexible or rigid manner. The accompanying drawings depict part of one of these duct sections together with electric pick-up means with which it is associated. As shown in the drawings the duct section 10 takes the form of a hollow box-like casing provided with an access slot 11 in one wall 17. An electric live rail or bus bar 13 is mounted within the duct section 10 and electric connection is made between the rails 13 of adjacent duct sections 10. Electric pick-up means 12 moves along the successive duct sections 10 and conveys electric current from the rails 13 via an electric cable 34 to some movable appliance, such as a mineral winning machine, (not shown) which would normally carry the pick-up means 12. Electrical connection is established between the cable 34 of the pick-up means 12 and the electric rails 13 by way of sliding contacts 14.
The slot 11 which is provided in the wall 17 of the casing of the duct section is sealed with the aid of separate seals 15,16. The seals 15,16 take the form of thin, resilient, wear-resistant steel strips having a width somewhat greater than the slot 11. The seal 15 is located inside the casing and engages on the inside surface of the wall 17 to cover the width and length of the slot 11 interiorly. Conversely, the seal 16 engages on the outside surface of the wall 17 to cover the width and length of the slot 11 exteriorly. Both seals 15,16 are held in sealing engagement with the wall 17 by means of permanent magnets 18 located on the edges of the slot 11. The pick up means 12 is adapted to deflect and lift the seals 15,16 away from the slot 11 locally as the pick up means progresses along the duct section in question to permit access to the rail 11. The pick-up means 12 employs, inter alia, a shaped member or slide piece 20 which engages in the slots 11 to run along the duct sections. The slide piece 20 is depicted separately in FIG. 5 and as shown, it has a generally H-shaped cross-section with a first portion located within the casing of the duct section and a second portion located outside the casing. An inner body or shoe 19 locates inside the casing of the duct section and is fixed to the first portion of the slide piece 20 and similarly an outer body or mounting piece 21 is fixed to the second portion of the slide piece 20 outside the casing. The shoe 19 is shaped to extend partly around the seal 15, and to this end the shoe 19 has a cavity or recess 22 facing the slot 11 into which the seal 15 can be deflected as the pick-up means 12 passes. At the side facing the inner surface of the wall 17, the shoe 19 carries seals 23 in the form of resilient strips maintained in contact with the inner surface of the wall 17, conveniently by means of spring-pressure. The seals 23 complement the sealing action of the strip seal 15 and maintain the cavity 22 sealed in respect of the interior of the casing outside the shoe 19. Likewise, the external mounting piece 21 is shaped to extend partly around the seal 16 and the mounting piece 21 has a cavity or recess 28 facing the slot 11 into which the seal 16 is deflected as the pick-up means 12 moves along the duct section. At the side facing the outer surface of the wall 17, the mounting piece 21 carries seals 29 in the form of resilient elastic strips maintained in contact with the outer surface of the wall 17. The seals 29 again complement the sealing action of the strip seal 16 and maintain the cavity 28 sealed in respect of the surroundings outside the mounting piece 21.
As shown in FIG. 5, the slide piece 20 has a central recess and tapered upper and lower surfaces 24,25, forming wedges, converging towards the outer ends of the slide piece 20. As shown in FIGS. 2 and 3, the first portion of the slide piece 20 (i.e. the upper portion of FIG. 5) engages inside the cavity 22 of the shoe 19 while the second portion of the slide piece 20 (i.e. the lower portion of FIG. 5) engages inside the cavity 28 of the mounting piece 21. The first portion of the slide piece 20 is laterally offset in relation to the cavity 22 and is secured at one side to the shoe 19 as indicated by reference numeral 27. The narrow central bridge region 25 of the slide piece 20 which interconnects the first and second portions thereof locates in the slot 11. The tapered surfaces, 24,25 of the slide piece 20 serve to smoothly and progressively deflect the strip seals 15,16 into the respective cavities 22,28 of the shoe 19 and the mounting piece 21, as shown in FIGS. 1, 2 and 4. The seals 23,29 however maintain the interior of the casing sealed in respect of the exterior. The shoe 19 is also provided with a device 30 which serves to bias the shoe 19 into sliding contact with the inner surface of the wall 17. As shown in FIG. 1, the device 30 takes the form of a lever supporting a roller 31 and a spring which acts on the lever to urge the roller 31 into rolling engagement with the inner surface of the upper wall of the casing opposite the slotted wall 17. Further rollers 32,33 are mounted at the ends of the cavities 22,28 of the shoe 19 and the mounting piece 21 to engage on the strip seals 15,16 to urge the seals 15,16 against the wall 17 inwardly of the seals 23,29. The rollers 32,33 thus act to hold the seals 15,16 just prior to their deflection by the slide piece 20 and to return the seals 15,16 after this deflection.
The electric cable 34 extends from the exterior laterally of the mounting piece 21 to enter the cavity 28 and thence passes through the central recess of the sliding piece 20 to enter the recess 22 in the shoe 19. From there, the cable 24 is led into the interior of the casing for connection with the contacts 14. The entry of the cable 34 to the cavities 22,28 is established without affecting the sealing thereof and for this purpose cable seals 35 (FIG. 2) can be provided. A conduit 36 is also mounted to the pick-up means 12 to supply a protective gas, e.g., nitrogen, to the interior of the casing. The conduit 36 is conducted into the interior of the casing in a similar manner to the cable 34. The protective gas can be supplied from a vessel carried by the mobile machine or appliance. The protective gas in the casing is above atmospheric pressure and since the interior of the casing is sealed from the exterior, it is only necessary to supply make-up gas to supplement any small leakage losses. In the event of more serious leakage, the protective gas flows from the interior of the casing to the exterior and due to the pressure differential, no explosive gas can enter the casing from the outside. Nevertheless, it is expedient to have additional devices which would disable the electric supply to the rails 13 should adverse conditions become established. Instead of employing thin metal strips as the seals 15,16 it is possible to use other materials. For example, the seals 15,16 can be made from wear-resistant reinforced synthetic plastics. Such a plastics strip seal can be impregnated with magnetic particles so that the magnets 18 can still be used to hold the strip seals in sealing engagement with the wall 17. Instead of using magnets 18, however, the seals 15,16 can be held against the wall 17 by means of other devices such as springs. Since the seal 15 can be effectively urged against the inner surface of the wall 17 by the pressure of the protective gas and since the inherent resilience of certain materials can act to hold the seals 15,16 against the wall 17, it is feasible to employ a construction wherein there are no special measures taken to urge the seals 15,16 against the wall 17. It is possible also to adapt the invention to the supply of hydraulic or pneumatic pressure medium. In this case the pressure medium is supplied to the interior of the duct sections and the electric pick-up means takes the form of a collector for the pressure medium. The rails 13 and the contacts 14 and the cables 34 are, of course, omitted. Otherwise, the duct sections with their seals 15,16 can take the form as described and/or illustrated with the shoe 19, the slide piece 20 and the mounting piece 21 serving as the carrier of the pressure medium collector and overall serving as collector means for the pressure medium. | A duct section serves as part of a supply system for supplying electric power or a pressure medium to a mobile appliance and especially to a mining machine in a mine working where protection against explosion or fire is necessary. The duct section has a wall with a longitudinal slot therein and pick-up engages in the slot to collect the electric current or pressure medium. The slot is sealed with the aid of thin flexible sealing strips held flat against the inner and outer surfaces of the slotted wall. The pick-up is shaped to progressively deflect the strips away from the slotted wall to permit the passage of the pick-up and maintains the interior sealing with the aid of further seals slidable engaging with the slotted wall over the region where the strips are deflected. | 4 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/552,209, now U.S. Pat. No. ______, filed on Sep. 1, 2009, the contents of which are incorporated herein by reference.
COPYRIGHT & TRADEMARK NOTICES
[0002] A portion of the disclosure of this patent document contains material, which is subject to copyright protection. The owner has no objection to the facsimile reproduction by any one of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights whatsoever.
[0003] Certain marks referenced herein may be common law or registered trademarks of third parties affiliated or unaffiliated with the applicant or the assignee. Use of these marks is for providing an enabling disclosure by way of example and shall not be construed to limit the scope of this invention to material associated with such marks.
TECHNICAL FIELD
[0004] The claimed subject matter relates generally to data storage systems and, more particularly, to re-establishing a backup relationship in a data storage system.
BACKGROUND
[0005] Various technologies (e.g., snapshot technology) may be used to backup data in a data storage system. Generally, in order to backup data stored in a primary volume (i.e., a source volume) in the storage system, a storage controller establishes a relationship between the primary volume and a secondary volume (i.e., a target volume) in the storage system such that the primary volume and the secondary volume are synchronized.
[0006] In existing storage systems, a user may be provided with the option to terminate the relationship between the primary volume and the secondary volume. Unfortunately, the relationship may only be terminated in its entirety such that the synchronization between the primary volume and the secondary volume is completely lost.
[0007] Unfortunately, once the relationship is terminated, re-establishing the relationship requires a complete re-synchronization of the primary volume and the secondary volume as if the volumes had never been synchronized before. Such implementation is inefficient and diminishes the performance of the storage system.
[0008] Systems and methods are needed to overcome the above-mentioned shortcomings.
SUMMARY
[0009] The present disclosure is directed to systems and corresponding methods that facilitate re-establishing a backup relationship in a data storage system.
[0010] For purposes of summarizing, certain aspects, advantages, and novel features have been described herein. It is to be understood that not all such advantages may be achieved in accordance with any one particular embodiment. Thus, the claimed subject matter may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages without achieving all advantages as may be taught or suggested herein.
[0011] In accordance with one embodiment, a method for re-establishing a backup relationship between first and second volumes associated with one or more storage media in a data storage system is provided. The method comprises storing first information for preserving the backup relationship, in response to or in advance of receiving a request to terminate the backup relationship; recording changes to the first or second volumes that occur subsequent to terminating the backup relationship; and re-establishing the backup relationship between the first and second volumes according to the first information such that the first and second volumes are synchronized by merging the recorded changes with the first or second volumes.
[0012] In accordance with another embodiment, a system comprising one or more logic units is provided. The one or more logic units are configured to perform the functions and operations associated with the above-disclosed methods. In accordance with yet another embodiment, a computer program product comprising a computer useable medium having a computer readable program is provided. The computer readable program when executed on a computer causes the computer to perform the functions and operations associated with the above-disclosed methods.
[0013] One or more of the above-disclosed embodiments in addition to certain alternatives are provided in further detail below with reference to the attached figures. The claimed subject matter is not, however, limited to any particular embodiment disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Embodiments of the claimed subject matter are understood by referring to the figures in the attached drawings, as provided below.
[0015] FIG. 1 illustrates an exemplary data storage system, in accordance with one or more embodiments.
[0016] FIG. 2 is a flow diagram of a method for terminating a relationship between a primary volume and a secondary volume, in accordance with one embodiment.
[0017] FIG. 3 is a flow diagram of a method for re-establishing a terminated relationship between a primary volume and a secondary volume, in accordance with one embodiment.
[0018] FIGS. 4 and 5 are block diagrams of hardware and software environments in which a system of the present invention may operate, in accordance with one or more embodiments.
[0019] Features, elements, and aspects of the claimed subject matter that are referenced by the same numerals in different figures represent the same, equivalent, or similar features, elements, or aspects, in accordance with one or more embodiments.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0020] In the following, numerous specific details are set forth to provide a thorough description of various embodiments of the claimed subject matter. Certain embodiments may be practiced without these specific details or with some variations in detail. In some instances, certain features are described in less detail so as not to obscure other aspects of the claimed subject matter. The level of detail associated with each of the elements or features should not be construed to qualify the novelty or importance of one feature over the others.
[0021] Referring to FIG. 1 , in accordance with one embodiment, an exemplary storage system 100 comprises a storage controller 110 and one or more storage devices 120 . The storages devices 120 comprise one or more primary volumes 122 and one or more secondary volumes 124 .
[0022] The storage controller 110 may establish an association or relationship between a primary volume 122 and a secondary volume 124 such that the primary volume 122 and the secondary volume 124 are synchronized (e.g., during a backup process). Synchronization between the primary volume 122 and the secondary volume 124 allows data stored on the primary volume 122 to be restored using data stored on the secondary volume 124 or vice versa.
[0023] Once the relationship is established, a user may terminate the relationship if services enabled or associated with the relationship (i.e., backup services) are no longer needed or desired. In some scenarios, the user may desire to re-establish a terminated relationship, for example, if the user terminated the relationship by mistake. Or, the user may desire to re-establish the relationship, for example, if the user temporarily terminated the relationship to recover resources allocated to backup services.
[0024] In one or more embodiments, the storage controller 110 may provide the user with the option to reversibly terminate (i.e., pseudo-terminate) a relationship between a primary volume 122 and a secondary volume 124 such that re-establishing the relationship does not require a complete re-synchronization between the primary volume 122 and the secondary volume 124 as if the volumes had never been synchronized before. Hereafter, for the purpose of clarity, the term pseudo-terminate is used to distinguish a permanent termination of a relationship between two storage volumes from a reversible termination.
[0025] In further detail and referring to FIGS. 1 and 2 , in accordance with one embodiment, the storage controller 110 may pseudo-terminate an association or relationship between a primary volume 122 and a secondary volume 124 . The storage controller 110 saves information associated with the relationship that would allow future re-establishment of the relationship (P 200 ). For example, the storage controller 110 may save the logical address of the secondary volume 124 or any data structures otherwise related to preserving the relationship between the primary volume 122 and secondary volume 124 .
[0026] Depending on configuration of the relationship, the relationship may involve incremental synchronization between the primary volume 122 and the secondary volume 124 . In incremental synchronization, multiple backups are generated for a storage volume: a full backup of the storage volume and one or more incremental backups of changes made to the storage volume since the full backup.
[0027] If it is determined that incremental backups exist (P 210 ), the storage controller 110 saves information associated with the incremental backups (P 220 ). For example, the storage controller 110 may save a target bitmap identifying data blocks that were changed on the primary volume 122 prior to the pseudo-termination, but have not yet been synchronized with the secondary volume 124 .
[0028] Upon saving the information associated with the relationship and any information associated with incremental backups, the storage controller 110 may complete pseudo-termination of the relationship by releasing resources allocated to the services enabled or associated with the relationship (P 230 ). As provided in further detail below, the storage controller 110 also activates one or more recording mechanisms for saving changes made to the primary volume 122 and the secondary volume 124 subsequent to the pseudo-termination of the relationship (P 240 ).
[0029] For example, in one implementation, the storage controller 110 may cause the primary volume 122 and the secondary volume 124 to enter a recording mode during which the storage controller 110 monitors write operations directed to the primary volume 122 and the secondary volume 124 . If the storage controller 110 receives a write operation directed to the primary volume 122 or the secondary volume 124 subsequent to the pseudo-termination of the relationship, the storage controller 110 may set a corresponding bit in a respective non-volatile bitmap to identify the data block that has been changed.
[0030] Referring to FIGS. 1 and 3 , in accordance with one embodiment, the storage controller 110 may re-establish the association or relationship between the primary volume 122 and the secondary volume 124 . To re-establish the relationship, the storage controller 110 utilizes information associated with the relationship that was saved prior to or during the pseudo-termination of the relationship, as provided above (P 300 ).
[0031] Once the relationship is re-established, the storage controller 110 synchronizes the primary volume 122 and the secondary volume 124 by merging changes made to the primary volume 122 and the secondary volume 124 saved by the recording mechanisms provided above subsequent to pseudo-termination of the relationship (P 310 ). For example, the storage controller 110 may merge the bits in a saved non-volatile bitmap identifying changed data blocks on the primary volume 122 with the bits in a saved non-volatile bitmap identifying changed data blocks on the secondary volume 124 . The storage controller may then synchronize the data blocks that are identified by the merged bits on the primary volume 122 and the secondary volume 124 .
[0032] If information associated with incremental backups was saved prior to or during the pseudo-termination (P 320 ), the storage controller 110 also merges the incremental backups (P 330 ). For example, the storage controller 110 may synchronize data blocks on the primary volume 122 that were changed prior to the pseudo-termination with corresponding data blocks on the secondary volume 124 . The changed data blocks may be identified using a saved target bitmap, as provided above.
[0033] Advantageously, there is no need to completely re-synchronize the primary volume 122 and the secondary volume 124 in order to re-establish the relationship between the primary volume 122 and the secondary volume 124 . Since each change made to the primary volume 122 and the secondary volume 124 after the last synchronization is saved, the relationship between the primary volume 122 and the secondary volume 124 may be re-established by synchronizing the saved changes such that synchronization of the entire primary volume 122 and the secondary volume 124 is not required.
[0034] In different embodiments, the claimed subject matter may be implemented either entirely in the form of hardware or entirely in the form of software, or a combination of both hardware and software elements. For example, storage system 100 may be included in a controlled computing system environment that may be presented largely in terms of hardware components and software code executed to perform processes that achieve the results contemplated by the system of the present invention.
[0035] Referring to FIGS. 1 , 4 , and 5 , a computing system environment in accordance with an exemplary embodiment is composed of a hardware environment 1110 and a software environment 1120 . The hardware environment 1110 comprises the machinery and equipment that provide an execution environment for the software; and the software provides the execution instructions for the hardware as provided below.
[0036] As provided here, the software elements that are executed on the illustrated hardware elements are described in terms of specific logical/functional relationships. It should be noted, however, that the respective methods implemented in software may be also implemented in hardware by way of configured and programmed processors, ASICs (application specific integrated circuits), FPGAs (Field Programmable Gate Arrays) and DSPs (digital signal processors), for example.
[0037] Software environment 1120 is divided into two major classes comprising system software 1121 and application software 1122 . System software 1121 comprises control programs, such as the operating system (OS) and information management systems that instruct the hardware how to function and process information.
[0038] In one embodiment, the storage controller 110 is implemented as application software 1122 executed on one or more hardware environments to re-establish a backup relationship in a data storage system. Application software 1122 may comprise but is not limited to program code, data structures, firmware, resident software, microcode or any other form of information or routine that may be read, analyzed or executed by a microcontroller.
[0039] In an alternative embodiment, the claimed subject matter may be implemented as computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer-readable medium may be any apparatus that can contain, store, communicate, propagate or transport the program for use by or in connection with the instruction execution system, apparatus or device.
[0040] The computer-readable medium may be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid-state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk read only memory (CD-ROM), compact disk read/write (CD-R/W) and digital video disk (DVD).
[0041] Referring to FIG. 4 , an embodiment of the application software 1122 may be implemented as computer software in the form of computer readable code executed on a data processing system such as hardware environment 1110 that comprises a processor 1101 coupled to one or more memory elements by way of a system bus 1100 . The memory elements, for example, may comprise local memory 1102 , storage media 1106 , and cache memory 1104 . Processor 1101 loads executable code from storage media 1106 to local memory 1102 . Cache memory 1104 provides temporary storage to reduce the number of times code is loaded from storage media 1106 for execution.
[0042] A user interface device 1105 (e.g., keyboard, pointing device, etc.) and a display screen 1107 can be coupled to the computing system either directly or through an intervening I/O controller 1103 , for example. A communication interface unit 1108 , such as a network adapter, may be also coupled to the computing system to enable the data processing system to communicate with other data processing systems or remote printers or storage devices through intervening private or public networks. Wired or wireless modems and Ethernet cards are a few of the exemplary types of network adapters.
[0043] In one or more embodiments, hardware environment 1110 may not include all the above components, or may comprise other components for additional functionality or utility. For example, hardware environment 1110 can be a laptop computer or other portable computing device embodied in an embedded system such as a set-top box, a personal data assistant (PDA), a mobile communication unit (e.g., a wireless phone), or other similar hardware platforms that have information processing and/or data storage and communication capabilities.
[0044] In some embodiments of the system, communication interface 1108 communicates with other systems by sending and receiving electrical, electromagnetic or optical signals that carry digital data streams representing various types of information including program code. The communication may be established by way of a remote network (e.g., the Internet), or alternatively by way of transmission over a carrier wave.
[0045] Referring to FIG. 5 , application software 1122 may comprise one or more computer programs that are executed on top of system software 1121 after being loaded from storage media 1106 into local memory 1102 . In a client-server architecture, application software 1122 may comprise client software and server software. For example, in one embodiment, client software is executed on a general computer (not shown) and server software is executed on a server system (not shown).
[0046] Software environment 1120 may also comprise browser software 1126 for accessing data available over local or remote computing networks. Further, software environment 1120 may comprise a user interface 1124 (e.g., a Graphical User Interface (GUI)) for receiving user commands and data. Please note that the hardware and software architectures and environments described above are for purposes of example, and one or more embodiments of the invention may be implemented over any type of system architecture or processing environment.
[0047] It should also be understood that the logic code, programs, modules, processes, methods and the order in which the respective steps of each method are performed are purely exemplary. Depending on implementation, the steps can be performed in any order or in parallel, unless indicated otherwise in the present disclosure. Further, the logic code is not related, or limited to any particular programming language, and may comprise of one or more modules that execute on one or more processors in a distributed, non-distributed or multiprocessing environment.
[0048] The claimed subject matter has been described above with reference to one or more features or embodiments. Those skilled in the art will recognize, however, that changes and modifications may be made to these embodiments without departing from the scope of the claimed subject matter. These and various other adaptations and combinations of the embodiments disclosed are within the scope of the claimed subject matter as defined by the claims and their full scope of equivalents. | A method for re-establishing a backup relationship between first and second volumes associated with one or more storage media in a data storage system is provided. The method comprises storing first information for preserving the backup relationship, in response to or in advance of receiving a request to terminate the backup relationship; recording changes to the first or second volumes that occur subsequent to terminating the backup relationship; and re-establishing the backup relationship between the first and second volumes according to the first information such that the first and second volumes are synchronized by merging the recorded changes with the first or second volumes. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mechanized excavating device for mounting on an auger crane to prepare a burial hole for utility pole and underbracing, and more specifically the hydraulic excavating auxiliary blades mounted at lower end of an extendable excavating screw unit is extendable and retractable by hydraulic pressure.
2. Description of the Related Art
Generally in the construction of power transmission and distribution lines and communication lines, utility poles are erected and electric and communication cables are installed on the poles. In this case, to respond the unbalanced tension of the electric and communication cables, a utility pole underbracing or guy wire is installed to prevent the utility pole from inclining or falling down. The utility pole underbracing is buried simultaneously with the utility pole after erecting the utility pole and excavating 0.5 m below the ground surface of the lower end of the utility pole. Next, to install the guy wire, excavation work for burial of the guy wire underbracing is carried out using man power or a machine. After that, guy wire underbracing is buried at the excavation point to be connected with the utility pole.
Normally, excavation work for installing such a utility pole underbracing or guy wire underbracing is done using an excavating screw fastened to an auger crane. Meanwhile, techniques for more achieving better quality and more efficient mechanized works are disclosed in prior art. For example, in Korean Patent Application No. 2005-126562 filed by the applicant of the present invention, as well as in Korean Utility Model Registration No. 0417120 and Korean Patent Application No. 2006-122020 are disclosed excavating screws for auger cranes having various types of retractable auxiliary blades.
However, because the excavating screws disclosed in these documents have a mechanism by which the auxiliary excavating blade is extended and retracted by manual rotation, many problems arise such as needing many workers, the difficulty of adjusting the auxiliary excavating blades, and the work time consumed to perform the adjustments.
So, an excavating screw in which auxiliary excavating blades of a type similar to the aforementioned are extended and retracted by hydraulic pressure is disclosed in Japanese Patent Laid-Open No. H13-73664. Since it is possible to remotely control the auxiliary excavating blades using hydraulic pressure in this excavating screw, it can be used economically and effectively. However, since the fluid transmission system is complicated in the auxiliary excavating blades having a hydraulic retracting means, actual application is difficult.
Meanwhile, both the excavating screw developed by the applicant of the present invention and the excavating screw with hydraulically extended and retracted auxiliary excavating blades can only be used for excavations of limited depth. Therefore, in the case of working on excavations deeper than the length of the excavating screw, an extendable excavating screw having an extension means should be used instead of the aforementioned excavating screw.
In an extendable excavating screw, an extension rod that can be inserted into and out of the excavating screw is inserted into the excavating screw. Since the total length of the excavating screw is varied according to the drawn-out length of the extension rod, excavation work is possible to deeper depths. Accordingly, if auxiliary excavating blades having a conventional rotation-type extending and retracting means are applied to an extendable excavating screw, operation is still difficult and cumbersome.
Therefore, the excavating screw used for deep excavation keenly requires auxiliary excavating blades and a hydraulic extending and retracting means to make more economic excavation possible.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an extendable excavating screw with hydraulic auxiliary excavation blades, wherein oil inflow and discharge passages (also referred to as fluid channels) are formed in an extension rod that is inserted into and out of the inside of the excavating screw, and separate auxiliary oil inflow and discharge passages are formed in the extension unit that is mounted on the bottom of the excavating screw, to apply hydraulic pressure continuously to the auxiliary excavating blades mounted on the lower extension unit even if the length of the extendable excavating screw is varied, so that the hydraulically operated auxiliary excavating blades can be used while varying the length of the excavating screw according to the required depth of the excavation and the work period is shortened and workability is improved.
In accordance with the present invention, there is provided an extendable excavating screw with hydraulic auxiliary excavating blades which has a tube-shaped excavation pipe, an extension unit that is combined with the lower end of the excavation pipe and has auxiliary excavating blades, a spiral screw placed on the outer circumference of the excavation pipe and extension unit, an extension rod installed in the excavation pipe such that it may extend or retract, and a coupler mounted at the upper end of the extension rod for attaching to an auger crane, the extendable excavating screw characterized in that: said coupler comprises an oil hose in which oil pumped from a fluid system flows in; said extension rod comprises an oil inflow passage for oil to flow in through said oil hose and an oil discharge passage for oil to be discharged through said oil hose; said extension unit comprises cylinder slots formed transversely at different heights; an actuating shaft which is mounted and able to slide in said cylinder slots in a transverse direction and at one end of which are fixed auxiliary excavating blades; main channels are formed in the extension unit for the oil flowing in and discharged through said oil inflow and discharge passages to flow; and oil pipes, one end of each of which is connected to said oil inflow and discharge passages and the other end of each of which is connected to the main channels through a fluid communication means, are placed between said extension unit and said extension rod inside the excavation pipe, and said oil pipes slide in said oil inflow and discharge passages in unison with the extension rod that is inserted into and out of the excavation pipe, so as to continuously apply hydraulic pressure on the actuating shaft having said auxiliary excavating blades through said main channels.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of an excavating screw according to the present invention.
FIG. 2 is an enlarged and exploded perspective view showing the major part of the excavating screw according to the present invention.
FIG. 3 is a perspective view showing the assembly of the whole excavating screw according to the present invention.
FIG. 4 is a sectional view showing the assembly of the whole excavating screw according to the present invention.
FIG. 5 is a sectional view of the major part showing the oil inflow and discharge passages in the excavating screw according to the present invention.
FIG. 6 is a sectional view showing a detail of the channels varied according to the adjusted length of the excavating screw according to the present invention.
FIG. 7 is a sectional view showing the state in which the auxiliary excavating blades of the excavating screw according to the present invention are extended by hydraulic pressure.
FIG. 8 is a sectional view showing the state in which the auxiliary blades of the excavating screw according to the present invention are retracted by hydraulic pressure.
FIG. 9 is a diagram schematically showing another example of channels formed on the excavating screw according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinafter, an extendable excavating screw with hydraulic auxiliary excavating blades of the present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 is an exploded perspective view of an excavating screw according to the present invention, FIG. 2 is an enlarged and exploded perspective view showing the major part of the excavating screw according to the present invention, FIG. 3 is a perspective view showing the assembly of the whole excavating screw according to the present invention, and FIG. 4 is a sectional view showing the assembly of the whole excavating screw according to the present invention.
An extendable excavating screw unit having hydraulic auxiliary blades of the present invention comprises a tube-shaped excavation column ( 20 ), an extension unit ( 10 ) that is attached to the lower end of the excavation column ( 20 ) has auxiliary excavating blades ( 11 , 11 ′), a spiral screw ( 21 ), an extension rod ( 30 ) extended and installed inside the excavation column ( 20 ), and a boss ( 31 ) formed at the top end of the extension rod ( 30 ) for attaching to an auger crane.
The boss ( 31 ) has connected to the hydraulic hose ( 33 ) to supply pressurized oil pumped from a fluid system. The extension rod ( 30 ) comprises an oil inlet ( 32 ) for oil inflow through the hydraulic hose ( 33 ), and an oil outlet ( 32 ′) for oil discharge through the hydraulic hose ( 33 ).
The extension unit ( 10 ) comprises a pair of the cylinder mounting holes ( 12 , 12 ′) in parallel to each other at different position, but perpendicular to the axis of the extension unit ( 10 ). A set of the cylinder ( 16 ) and piston ( 17 ) are mounted in the cylinder mounting holes ( 12 , 12 ′) oriented opposite direction and auxiliary excavating blades ( 11 , 11 ′) are fixed at one end thereof. A pair of the built-in fluid passages ( 15 , 15 ′) is formed inside the extension unit ( 10 ) for oil supplying and discharging through the built-in hydraulic tube ( 14 , 14 ′). The other ends of the built-in fluid passages ( 15 , 15 ′) are connected to the cylinders ( 16 ) and pistons ( 17 ).
An excavation column ( 20 ) has a square-shape hollow center, and a bottom end of the excavation column ( 20 ) mounted on top of the extension unit ( 10 ).
An extension rod ( 30 ) has an outer square-shape to fit into the excavation column ( 20 ), and a pair of built-in hydraulic tube ( 14 , 14 ′) formed in the extension rod ( 30 ). The top portion of the hydraulic passages in the extension rod ( 30 ) has bent right angle to form an inlet and outlet ( 32 , 32 ′) for connecting to hydraulic hose ( 33 ). The extension rod ( 30 ) is inserted into the excavation column ( 20 ) for extending or retracting. The oil inlet and outlet ( 32 , 32 ′) is connected to the other end of the hydraulic tube ( 14 , 14 ′) formed in the extension rod ( 30 ). A pair of the flexible hydraulic hoses ( 51 , 51 ′) is connected to built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ) through the hydraulic tube ( 14 , 14 ′) formed in the extension rod ( 30 ) and the oil inlet and outlet ( 32 , 32 ′).
When the extension rod ( 30 ) moves to slide along with the excavation column ( 20 ), the flexible hydraulic hoses ( 51 , 51 ′) are expending or contracting in unison. So that the hydraulic pressure is continuously supplied through the oil inlet and outlet ( 32 , 32 ′) to the built-in hydraulic tube ( 14 , 14 ′) in the extension rod ( 30 ) and the built-in fluid passages ( 15 , 15 ′) extension unit ( 10 ) to the piston ( 17 ) being attached the auxiliary excavating blades ( 11 , 11 ′).
Also, the extendable excavating screw unit of the present invention further comprises a mounting plate ( 50 ) disposed in the excavation column ( 20 ) for mounting the flexible hydraulic hoses ( 51 , 51 ′). The built-in hydraulic tube ( 14 , 14 ′) in the extension rod ( 30 ) is connected to the flexible hydraulic hoses ( 51 , 51 ′), which is fixed on the mounting plate ( 50 ) and the other end of the hydraulic hoses ( 51 , 51 ′) connected to communicate with the built-in fluid passages ( 15 , 15 ′) of the extension unit ( 10 ).
Therefore, when the excavation column ( 20 ) begins to rotate, the extension unit ( 10 ) will be twisted relative to the rotation. Then, the flexible hydraulic hoses ( 51 , 51 ′) will offset the relative twist to prevent the damage on the built-in hydraulic tube ( 14 , 14 ′) in the excavation column ( 20 ).
At this time, as shown in the enlargement in FIG. 7 , the ends of the built-in hydraulic tube ( 14 , 14 ′) and flexible hydraulic hoses ( 51 , 51 ′) are sealed and assembled by the retainers. At the lower end of the extension rod ( 30 ), the retainers are also installed to prevent oil leaking while the built-in hydraulic tube ( 14 , 14 ′) are sliding along the oil passages in the extension rod ( 30 ). The built-in hydraulic tube ( 14 , 14 ′) is sliding smoothly.
In the cylinder mounting holes ( 12 , 12 ′) of the extension unit ( 10 ), the cylinder ( 16 ) is mounted for supporting the piston ( 17 ) attached the auxiliary excavating blades ( 11 , 11 ′) at its ends. One end of the cylinder ( 16 ) is inserted to mount on the cylinder mounting holes ( 12 , 12 ′) and the other end is protruded from one side of the extension unit ( 10 ). The pistons ( 17 ) are inserted into the cylinder ( 16 ) through the opposite end of the installed cylinder ( 16 ). A fluid chamber ( 17 a ) is formed at the center of the pistons ( 17 ) for installing a piston shaft ( 18 ). An end flange integrally formed with the piston shaft ( 18 ) is fixed to the end of the cylinder mounting holes ( 12 , 12 ′) of the extension unit ( 10 ), and the piston shaft extended from the end flange to be inserted into the fluid chamber ( 17 a ). At the end portion of the piston shaft ( 18 ), a piston ring ( 19 ) is installed for slide-contacting with the inner wall of the fluid chamber ( 17 a ) of the piston. At a tip of the piston shaft ( 18 ), a bushing-retainer is installed in front of the piston ring ( 19 ) to prevent oil leakage.
The fluid chamber ( 17 a ) formed in the piston ( 17 ) is partitioned into two regions by the piston ring ( 19 ). The piston shafts ( 18 ) have formed the built-in fluid passages ( 19 a , 19 b ) in the piston shafts ( 18 ). One end of the built-in fluid passages ( 19 a , 19 b ) in the piston shafts ( 18 ) communicates with the built-in fluid passages ( 15 , 15 ′) of the extension unit ( 10 ). The other ends of the built-in fluid passages ( 19 a , 19 b ) are exposed to the fluid chamber ( 17 a ) divided by the piston ring ( 19 ). Thus, the pressurized oil supplied into the fluid chamber ( 17 a ) is activated the pistons ( 17 ). Accordingly, the length of the piston ( 17 ) is extended or retracted by the oil supply or discharge into the fluid chambers ( 17 a ) partitioned by the piston ring ( 19 ).
As shown in FIG. 9 , the valve mounting seats ( 40 , 40 ′) are formed inside top portion of the extension unit ( 10 ), and the check valves ( 41 , 41 ′) are mounted to the valve mounting seats ( 40 , 40 ′). The double pilot check valves ( 41 , 41 ′) are selectively connected to the built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ) and the built-in fluid passages ( 19 a , 19 b ) in the piston shafts ( 18 ). The auxiliary excavating blades ( 11 , 11 ′) are extended and maintained by the pressurized fluid to prevent retraction due to the digging resistance.
The configuration of the extendable excavating screw unit of the present invention will be described in more detail. The extendable excavating screw unit has the excavation column ( 20 ), which is inserting the extension rod ( 30 ) for performing the deep excavation work. A boss ( 31 ) is formed at the top end of this extension rod ( 30 ) for mounting the excavating screw unit to a conventional auger crane.
Also, the lower end of the excavation column ( 20 ) is mounted to the extension unit ( 10 ) having attached the auxiliary excavating blades ( 11 , 11 ′). A spiral screw ( 21 ) is formed on the outer circumference of the excavation column ( 20 ) and the extension unit ( 10 ) along with the entire length of the excavation column ( 20 ).
The excavating screw unit is constructed in such a way that the auxiliary excavating blades ( 11 , 11 ′) are extended and retracted by the pressurized fluid supplied from the fluid system.
For this, the oil inlet and outlet ( 32 , 32 ′) are formed in parallel along with the extension rod apart with constant distance. The oil inlet and outlet ( 32 , 32 ′) are formed at the boss ( 31 ) to be connected the hydraulic hose ( 33 ) for supplying the oil from the fluid system. Therefore, the hydraulic hose ( 33 ) is connected to the oil inlet and outlet ( 32 , 32 ′) to communicate with the oil supplied from the fluid system.
Also, the extension unit ( 10 ) is attached to the excavation column ( 20 ), and the extension rod ( 30 ) is inserted into the excavation column ( 20 ), such that it can be extend. Namely, the extension rod ( 30 ) allows sliding the total length of the excavating screw unit to adjust by extending outward along with the excavation column ( 20 ) or retracting into the excavation column ( 20 ). At this time, the built-in hydraulic tubes ( 14 , 14 ′) are inserted to the extension rod ( 30 ). The oil inlet and outlet ( 32 , 32 ′) are connected to the built-in hydraulic tubes ( 14 , 14 ′) in the extension rod ( 30 ). Further, the built-in hydraulic tube ( 14 , 14 ′) are connected to the flexible hydraulic hoses ( 51 , 51 ′) fixed on the mounting plate ( 50 ) to communicate with the built-in fluid passages ( 15 , 15 ′) formed in the extension unit ( 10 ).
Namely, as shown in FIG. 5 and FIG. 6 , the built-in hydraulic tube ( 14 , 14 ′) and the flexible hydraulic hoses ( 51 , 51 ′) are located in the excavation column ( 20 ) for fluid communication with the oil inlet and outlet ( 32 , 32 ′) during the extension rod ( 30 ) extended or retracted from the excavation column ( 20 ). The fluid communication between the oil inlet and outlet ( 32 , 32 ′) and built-in fluid passages ( 15 , 15 ′) is maintained through the built-in hydraulic tube ( 14 , 14 ′) and the flexible hydraulic hoses ( 51 , 51 ′).
The auxiliary excavating blades ( 11 , 11 ′) are actuated by the pressurized oil supplied through the built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ), the flexible hydraulic hoses ( 51 , 51 ′) and the built-in hydraulic tube ( 14 , 14 ′). The auxiliary excavating blades ( 11 , 11 ′) are operated in such a way that the pressurized oil supplied is supplied to the fluid chambers ( 17 a ) of the left and right pistons ( 17 ), so that the left and right auxiliary excavating blades ( 11 , 11 ′) are extended. Therefore, it is possible for auxiliary excavating blades ( 11 , 11 ′) located at different heights and opposite direction to sliding out or in while the screw is simultaneously advancing or retreating by the supplying of the fluid.
Also, the cylinder mounting holes ( 12 , 12 ′) in the extension unit ( 10 ) are formed in opposite directions at different location of heights. Inside the cylinder mounting holes ( 12 , 12 ′), the tube-shaped cylinders ( 16 , 16 ′) are inserted and fixed to protrude out of the extension unit ( 10 ). Into the cylinder 16 is inserted the piston ( 17 ) having auxiliary excavating blades ( 11 , 11 ′) at one end.
In particular, the fluid chamber ( 17 a ) formed a hollow cavity is provided at the center of the piston ( 17 ). The piston shaft ( 18 ) is inserted into the fluid chamber ( 17 a ). The other end of the piston shaft ( 18 ), an end flange is integrally formed with a plurality of fastening holes for bolts to a flange mounting seats formed at the other ends of the cylinder mounting holes ( 12 , 12 ′) with a plurality of corresponding fastening holes. Therefore, the flange of the piston shaft ( 18 ) is firmly fixed to the cylinder mounting holes ( 12 , 12 ′) by a plurality of bolts fastened through these fastening holes. The piston ring ( 19 ) is installed at the tip portion of the piston shaft ( 18 ) for sealing and contacting with the inner wall of the fluid chamber ( 17 a ). The built-in fluid passages ( 19 a , 19 b ) are formed along the axis of the piston shaft ( 18 ), as shown in FIG. 7 .
One end of the built-in fluid passages ( 19 a , 19 b ) is connected to the built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ), and the other end of the built-in fluid passages ( 19 a , 19 b ) is connected the fluid chamber ( 17 a ) for fluid communication. Accordingly, the fluid chamber ( 17 a ) is partitioned by the piston ring ( 19 ) for activating the piston ( 17 ). When the pressurized fluid is supplied to the fluid chamber ( 17 a ) through the built-in fluid passages ( 19 a , 19 b ) in the piston shaft ( 18 ) and the built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ), the piston ( 17 ) is actuated to extending. While the piston ( 17 ) is moving in the direction of the arrow, the piston ring ( 19 ) is relatively sliding along the inner wall of the fluid chamber ( 17 a ). Therefore the auxiliary excavating blade ( 11 ) is effectively extended to the desired length. At the same time, the fluid in the other vicinity partition of the fluid chamber ( 17 a ) is discharged through the built-in fluid passages ( 19 a , 19 b ) in the piston shaft ( 18 ) and the built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ).
Conversely, as shown in FIG. 8 , when the fluid is supplied to the other side of the fluid chamber ( 17 a ) partitioned by the piston ring ( 19 ) through the built-in fluid passages ( 19 a , 19 b ) in the piston shaft ( 18 ) and the built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ), the piston ( 17 ) is actuated to retracting. Then, the piston ring ( 19 ) is relatively sliding along the inner wall of the fluid chamber ( 17 a ) by the hydraulic pressure, while the piston ( 17 ) is retreating in the direction of the arrow. Therefore, the auxiliary excavating blade ( 11 ) is effectively decreasing its length. At the same time, the oil in the neighbored partition of the fluid chamber ( 17 a ) is discharged through the built-in fluid passages ( 19 a , 19 b ) in the piston shaft ( 18 ) and the built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ).
As described above, the fluid supplied or discharged from the oil inlet and outlet ( 32 , 32 ′) flows through the built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ) and the built-in fluid passages ( 19 a , 19 b ) in the piston shaft ( 18 ) to actuate the piston ( 17 ) extended or retracted.
Therefore, it is possible to conveniently remote-control the extending or retracting of the auxiliary excavating blades ( 11 , 11 ′) by applying the hydraulic pressure. It is also possible to use the excavating screw unit more economically and effectively for deep excavating works as well as excavation for a given depth.
When, the extended auxiliary excavating blades is rotated by the excavating screw unit, the extension rod ( 30 ) disposed in the excavation column ( 20 ) will be relatively twisted due to the excavating resistance of the extension unit ( 10 ). Namely, when the torque applied to the vertical axis of the excavation column ( 20 ), the occurrence of twist is different along the assembly of the extension rod ( 30 ) and the extension unit ( 10 ). If the twist is considerably occurred, the loads would be affected to the built-in hydraulic tube ( 14 , 14 ′). If the twist is severe, the built-in hydraulic tube ( 14 , 14 ′) will be twisted or damaged to cause a malfunction.
In particular, if the extension rod ( 30 ) in the excavation column ( 20 ) is expanded down to the maximum, the twist will be increased maximum by the applied load as mentioned above. If the twist goes beyond the allowed limitation, the built-in hydraulic tube ( 14 , 14 ′) will be seriously damaged or deformed to cause the fluid leakages.
To prevent this incident, the mounting plate ( 50 ) is installed inside the lower portions of the excavation column ( 20 ) for fixedly mounting the lower ends of the built-in hydraulic tube ( 14 , 14 ′). At the mounting plate ( 50 ), a pair of couplings installed to couple the flexible hydraulic hoses ( 51 , 51 ′). The built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ) are connected to the other end of the flexible hydraulic hoses ( 51 , 51 ′).
Ultimately, the twist is occurred between the extension unit ( 10 ) and the extension rod ( 30 ) in the excavation column ( 20 ) during the rotation of the excavation screw unit. However, the flexible hydraulic hoses ( 51 , 51 ′) will be effectively absorbed to offset the most twist occurrence. Because the flexible hydraulic hoses ( 51 , 51 ′) are made of relatively soft and strong elastic material, it will absorb a certain level of the twist to prevent the interruption of the fluid supply. Thus, it is possible to provide the fundamentally solution of the aforementioned problem.
Moreover, the mounting plate ( 50 ) is located inside of the excavation column ( 20 ) for fixedly mounting the built-in hydraulic tube ( 14 , 14 ′), it will safely and stably protecting the built-in hydraulic tube ( 14 , 14 ′) during the rotation of the excavation screw unit.
The extendable excavating screw unit with the hydraulic auxiliary excavating blades of the present invention can be used a method of continuously supplying the fluid to maintain the extended position when the auxiliary excavating blades ( 11 , 11 ′) are extended and held by the hydraulic pressure. Because the conventional fluid transmission system has a considerable trouble and shock problems when the loads are applied during excavation, it is preferable to use a fluid control technique by adopting the check valves.
As shown in FIG. 9 , the valve mounting seats ( 40 , 40 ′) are formed at the lateral side of the extension unit ( 10 ) in a opposite direction, and the double pilot check valves ( 41 , 41 ′) are mounted on the valve mounting seats ( 40 , 40 ′). The double pilot check valves ( 41 , 41 ′) are connected to the built-in fluid passages ( 15 , 15 ′) in the extension unit ( 10 ) and the built-in fluid passages in the ( 19 a , 19 b ) in the piston shaft ( 18 ) for supply the fluid from the inlet and outlet ( 32 , 32 ′).
Namely, when the fluid is supplied from the oil inlet ( 32 ) to one side, the pertinent quantity of fluid is allowed to be discharged through the oil outlet ( 32 ′) of the opposite side. When the fluid supply is ended, the fluid passages opened by the double pilot check valves ( 41 , 41 ′) are shut off to prevent excessively pressurizing the fluid to cause a leaking. Therefore, the auxiliary excavating blades ( 11 , 11 ′) are actuated by the properly pressurized fluid for preventing retracting back due to external force of the digging resistance.
Conversely, when the other side of the fluid is drained to the oil outlet ( 32 ′), the one side of the fluid is supplied to open the oil inlet ( 32 ). Such a process, the auxiliary excavating blades ( 11 , 11 ′) are extended or retracted from the cylinders ( 16 , 16 ′). When the retraction is completed, the supply of the fluid is cut-off by the double pilot check valves ( 41 , 41 ′).
Therefore, the auxiliary excavating blades ( 11 , 11 ′) are popped in or out only when the double pilot check valves ( 41 , 41 ′) is opened or closed by the control of the operator.
Since in the extendable excavating screw with hydraulic auxiliary excavating blades the hydraulic pressure continuously acts on the auxiliary excavating blades of the lower extension unit while the excavation length of the extendable excavating screw varies, it is possible to work effectively according to the depth of excavation by using the extendable excavating screw with auxiliary blades operated by hydraulic pressure, so the construction period is shortened and workability is greatly improved.
Although the present invention has been described in detail with reference to its presently preferred embodiment, it will be understood by those skilled in the art that various modifications and equivalents can be made without departing from the spirit and scope of the present invention, as set forth in the appended claims. | An excavating screw unit equipped with a hydraulic excavating auxiliary blades has developed for an auger crane, comprising: an extension unit having auxiliary excavating blade, cylinder mounting hole, built-in fluid passages in extension unit, hydraulic cylinder, piston, and extension guiding rods; an excavation column formed a hollow center of a square-shaped to mount on top of extension unit; an extension rod having an outer square-shape to fit into the excavation column, a built-in hydraulic passages in the extension rod, at top portion of the extension rod, an inlet and outlet that is bent right angle at top portion of the hydraulic passages to connect to hydraulic tubes, the extension rod is sliding to extend or retract through the excavation column. The extended excavating auxiliary blades are maintained by the pressurized fluid to prevent retracting by digging resistance during the excavating. Thus, this mechanized excavating device is easily digging a burial hole for a utility pole and underbracing. | 4 |
Reference to related patents, the disclosure of which is hereby incorporated by reference:
U.S. Pat. No. 5,179,468, Gasloli
U.S. Pat. No. 5,138,219, Krisl et al
U.S. Pat. No. 4,249,101, Walsh
U.S. Pat. No. 4,721,877, Kawakatsu et al
U.S. Pat. No. 4,869,927, Kawakatsu et al, a division of U.S. Pat. No. 4,721,877
U.S. Pat. No. 4,663,557, Martin et al.
Reference to related publications:
Published European Patent Application 0 470 496 A2, Yuge et al Published European Patent Application 0 460 913 A2, Watanabe.
FIELD OF THE INVENTION
The present invention relates to a reflector lamp, and more particularly to such a reflector lamp which is especially suitable for use in a housing or lamp fixture or luminaire, in which the lamp is so constructed that it does not overheat the housing or fixture within which it may be retained, the light source itself being in form of a halogen lamp, typically a halogen incandescent lamp.
BACKGROUND
Reflector-type halogen incandescent lamps are well known, and European Published Patent Applications 0 460 913 A2, Watanabe, and 0 470 496 A2, Yuge et al, illustrate typical examples. The halogen incandescent lamps there shown have a coating which transmits visible light, but reflects infrared (IR) radiation into the interior of the lamp. Such coatings are also known as a warm or hot-light mirror. The lamp is fitted into a reflector. The reflector has a glass shell which is coated at its interior with an interference filter material, which reflects visible light, but transmits IR radiation. Such a reflector is also known as a visible light or cold-light mirror. Such lamps are particularly suitable for illuminating relatively cool objects. If this lamp is located within a lamp housing, the fixture is subject to substantial heat loading due to the cold-light mirror, which passes the IR radiation backwardly of the reflector mirror.
THE INVENTION
It is an object to so construct a reflector lamp that the heat radiation in the direction of visible light radiation is reasonable and acceptable for most uses without, however, at the same time overloading the fixture or housing of the lamp with respect to heating thereof.
Briefly, the light source or lamp is so constructed that infrared radiation from the bulb is diffusely emitted therefrom; and the reflector reflects both visible light as well as a portion, preferably a substantial proportion of infrared radiation.
In accordance with the invention, therefore, the emitted infrared radiation towards the rear of the lamp, that is, through the reflecting mirror, is only a minor portion of the infrared radiation; the infrared radiation is emitted in the direction of the visible light but, before being so emitted, is so influenced that it is radiated in a diffuse manner, rather than in the directional pattern resulting from the reflector located to reflect the visible radiation in a predetermined manner and direction. Consequently, only the visible, needed radiation is projected by the reflector; the unfocused, diffuse infrared radiation is uniformly distributed from the lamp.
In accordance with a preferred feature of the invention, a light emitting filament, for example, is so located with respect to the reflector that it is axially positioned within the reflector axis, so that the proportion of direct radiation which leaves the reflector, without deflection therefrom, is minimized. It is readily possible to shield the end of the bulb of the light source or, for example, to use any one of the well known coatings, for example a metal oxide as described in Published European Patent Application 0 460 913 A2, Watanabe. It is not necessary that the filament be axially located; transversely positioned filaments are also suitable.
In accordance with the invention, so constructing the lamp that it has means which cause diffusion of infrared radiation from the light source without, however, modifying the visible radiation, results in an overall construction in which the lamp functions, as before, as a source of visible radiation; its undesirable feature, namely a source of infrared (IR) radiation, is then not the filament as such but, rather, the entire bulb within which it is retained. The outer dimensions of the bulb are not matched to the directional characteristics of the reflector, and are much larger than the filament itself.
The diffuse radiation of the IR portion can be obtained, in accordance with a preferred feature of the invention, by using a customary interference coating which acts as a warm-light reflector or mirror. The radiation edge between the region of high transmission--that is, visible light having a wave length of between about 400-800 nm--and a range of high reflection, that is, infrared radiation having a wave length longer than about 800 nm, is preferably in the range of between 700-900 nm. The high reflectivity of the coating results in multiple reflection paths of the IR radiation within the bulb itself so that, for purposes of IR radiation, the entire bulb forms the radiation source therefor, rather than only the filament placed essentially in a focal position of the reflector.
Various types of coatings can be used.
EXAMPLE 1
A plurality of coatings, that is, a stack of coatings, alternatingly with a high and low index of refraction, are formed. These coatings include, for example, TiO 2 , Ta 2 O 5 or Nb 2 O 5 , and SiO 2 , MgF 2 respectively. Such coatings are described, for example, in the referenced U.S. Pat. Nos. 5,179,468, Gasloli, or 5,138,219, Krisl et al. Depending on the dimension of the stack of the respective coatings, these coatings can be used as cold-light mirrors as well as warm-light mirrors or, also, as wide-band mirrors--see U.S. Pat. No. 4,663,557, Martin et al.
EXAMPLE 2
As an alternative to the coatings of Example 1, coatings on a basis of metal, for example silver, can be used; such coatings are selectively infrared-reflective. Reference is made to U.S. Pat. No. 4,249,101, Walsh, with respect to such coatings, which may include silver, gold, aluminum, and the alkali metals. This patent also discloses a coating of two layers of metal, such as silver, sandwiching a dielectric material therebetween to form an etalon coating.
EXAMPLE 3
As another alternative to the above examples, coatings which contain organometallic compounds which form bubbles may be used. These bubbles have IR radiation diffusing or dispersing effect, see U.S. Pat. Nos. 4,721,877 and 4,869,972, Kawakatsu et al (to which European Specification 0 176 345 B1 corresponds).
EXAMPLE 4
IR absorbing layers may be used which re-radiate the absorbed heat; such layers may, for example, be thin gold layers.
Basically, the invention is directed to the feature that the lamp bulb is supplied with a means which causes diffuse radiation of the IR radiation component from the surface of the bulb of the lamp. The above four examples give suitable coatings.
The diffuse or unfocused emitted IR radiation permits use of a reflector which acts as a broad band mirror, reflecting visible light as well as a substantial portion of the IR radiation. Consequently, it reflects at least the portion of the IR radiation in a wave length of between about 800 and 1200 nm, adjacent a visible light band since, in this wave length, the emission of radiation from the incandescent lamp is the maximum. The selection of the cut-off or edge of reflection permits optimum balancing of heat loading in the direction of the emitted radiation, that is, towards the opening of the reflector, and backwardly, that is, back of the reflector towards the lamp base, and hence towards a lamp housing, or fixture, or luminaire.
A suitable reflector, which meets the requirement, is an aluminum reflector which reflects a broad band of wave lengths, and particularly well between 300 nm to more than 3000 nm. Especially suitable is a reflector cup or shell which is coated with a broad-band interference filter coating. The shell may be of glass or plastic. The short-wave reflection edge is, preferably, in the range of about 400 to 450 nm; the long-wave edge is preferably between about 1200 and 2000 nm, 1500 nm being particularly suitable. This arrangement can be more easily optimized with respect to the desired result, that is, desirably minimum thermal loading in forward direction, than an aluminum reflector, in which the transmission or reflection characteristics are essentially predetermined. A massive aluminum reflector, however, has the advantage that it is essentially insensitive with respect to mechanical damage and, especially, with respect to heat. In principle, a metal, particularly aluminum, may form a substrate which is coated with the suitable interference filter coating.
The preferred transmission of the bulb, in the visible wave length, should be better than 90%. A preferred reflection of the reflector in the range of the broad-band mirror should also be better than 90%, or 0.9. A portion of the remaining transmission may extend through the reflector, if it is partly transparent, towards the lamp fixture or housing, within which the lamp is retained. This is entirely acceptable if this remaining transmission is in the order of between about 0.5 and 2% of the overall luminous flux. In the visible radiation range, such remaining deflection provides an aesthetically pleasing appearance of the lamp unit as a whole.
Reflector lamps which are customarily used for general service illumination have power ranges between about 20 W to 100 W and even more. The reflector lamp in accordance with the present invention is particularly suitable for such power ratings and especially for use in energy-efficient lamps in which the bulb is so shaped that the light output is increased, because IR radiation is particularly effectively re-reflected to the light emitting element or body itself, thereby increasing its temperature. Generally spherical or cylindrical or ellipsoidal or similar configurations of bulb shapes for the lamp bulb are suitable.
DRAWINGS
FIG. 1 is a side view, partly in section, of a reflector lamp in accordance with the invention;
FIG. 2 is a view similar to FIG. 1 of another reflector lamp;
FIG. 3 is a graph of spectral reflection (ordinate) with respect to wave length, and illustrating the effects of various types of reflectors, as well as, in highly schematic form, of radiation from the lamp. Lamp radiation is also indicated, to a different scale and in percentages, on the ordinate of the graph; and
FIGS. 4a to 4d are spatial distribution diagrams of radiation when using different types of reflectors.
DETAILED DESCRIPTION
Referring first to FIG. 1:
The lamp has a reflector element 1 in which a 12 V low-voltage halogen incandescent lamp 2 is secured. The lamp 2 has a nominal rating of 50 W, and it is positioned on the axis of symmetry of a rotation-symmetrical aluminum reflector 5. This aluminum reflector may either be a reflector made of solid aluminum of high purity; alternatively, it may be made of a substrate of glass which is coated with an aluminum coating 4; this is the embodiment shown. The lamp is securely retained within the reflector by a cement 8. The longitudinal axis of the halogen incandescent lamp 2 and the axis of symmetry of the reflector 5 are congruent. The filament 3 of the halogen incandescent lamp is axially located and positioned at, or close to, the focal point of the reflector 5. Since the filament 3 has a finite dimension and is not a theoretical point like a focal point, it is actually located in a surface or focal region of the reflector 5. The reflector 5 is closed with a closing disk or cover 6. The bulb 2a of the lamp 2 is a cylinder of quartz glass or hard glass.
In accordance with a feature of the invention, the bulb 2a is coated at the outside, or at the inside, or both at the outside and the inside, with an IR reflective, diffusing or dispersing or absorbing coating 7. The coating 7 may be in accordance with the Examples 1-4 above. The lamp 2 is located within a lamp housing or light fixture which is only shown schematically by chain-dotted line 9, since it may be of any suitable configuration.
FIG. 3 illustrates the spectral reflection of an aluminum reflector 5. The reflection extends, at the long wave length, to close to 4000 nm, and hence reflects the essential portion of radiation from the lamp 2. This radiation distribution is shown, highly schematically in block form, in solid lines, in FIG. 3, for comparison purposes. Of course, actually, the radiation will not be in the stepped form shown, which is merely a schematic representation.
The lamp of FIG. 2 corresponds in all essential features to the lamp of FIG. 1; rather than using an incandescent lamp with a generally cylindrical bulb, the incandescent lamp 10 has an essentially ellipsoidal bulb 13. It is coated with an interference filter 11 having more than 20 layers of Ta 2 O 5 /SiO 2 . This is a well known warm-light filter, transmitting radiation between about 400 and 800 nm, but reflecting radiation above 800 nm. The transmission of visible light is about 90%, and IR reflection is about 65%. The thickness of the reflective layers is roughly constant over the surface of the bulb.
The reflector 5 is formed by a substrate of glass, coated at the inside with an interference filter 12 made of TiO 2 /SiO 2 , having more than 20 layers, and acting as a wide-band mirror. It reflects in a range of wave length between about 400 and 1500 nm of more than 90%. The thickness of the respective layers may vary over the surface of the reflector. The spectral reflection is shown in FIG. 3 by the chain-dotted line. Above the limit of about 1500 nm, the contribution of IR radiation of the lamp 10 is in a tolerable order of magnitude; in other words, the radiation between about 1500 nm and 4000 nm is such that it can be partially or even completely emitted towards the rear of the lamp, that is, not through the front cover 6. If required, for example by a housing shown in broken lines 29 in FIG. 2, the design of the layers of the broad-band reflector can be so made that it is partially transmitting in the long-wave IR portion of the spectrum, for example 70% transmissive.
A further contribution of about 15% of radiation is emitted by the diffuse bulb radiation in the range of between about 4000 and 10,000 nm. Preferably, the characteristic of the bulb material itself can be used there, which absorbs radiation from about 4000 nm of the filament, and thus, within the concept of the present invention contributes additionally to diffuse IR radiation. The lamp bulb material, usually, is quartz glass or hard glass. Thus, a filter acting in the range above about 4000 nm is not needed.
Of course, the type of bulb shown in FIG. 1 may also be used in the embodiment of FIG. 2, that is, an interference filter coating may also be used in the embodiment of FIG. 1.
FIG. 3 provides a comparison of the reflection characteristics of a cold-light mirror, described in connection with the prior art, which only reflects visible portions of radiation, with the present invention.
FIG. 4 is a highly schematic representation of radiation diagrams of different reflectors. The bulbs are shown only schematically, and may, for example, be ellipsoidal, as illustrated, or cylindrical, or spherical (FIGS. 1, 2). The radiation patterns are schematic, and not to scale.
In FIG. 4, the solid line symbolizes the visible radiation; the broken lines the IR portion of emitted radiation. FIG. 4a illustrates a customary reflector lamp having an uncoated bulb and aluminum mirror. The light distribution of visible radiation and IR radiation are practically coincident. The heat loading in forward direction from the lamp is very high.
FIG. 4b illustrates a reflector lamp having a cold-light mirror (KLR) in accordance with the prior art described in the background portion of this specification. As can be clearly seen, a lamp housing or light fixture 9 (FIG. 1) or 29 (FIG. 2) surrounding the lamp would be substantially heated due to the effect of the rear-emitted IR radiation. A remaining portion of the IR radiation is projected forwardly, in a directed pattern.
FIG. 4c illustrates one embodiment of the present invention using a reflector lamp with an infrared coating of the bulb, as well as a broad band coating of the reflector. Both coatings are interference filters. The infrared radiation is largely emitted forwardly, as shown in FIG. 4a, however, as clearly apparent from FIG. 4c, in diffuse and non-focused manner, and essentially uniformly distributed. Thus, heat loading in a small target area, to which the visible light cone is directed, is effectively avoided. The heat energy radiated--highly diffused--in the direction of the light beam, is only slightly more than that in the lamp of FIG. 4b, resulting in lower heat energy transmission rearwardly of the lamp.
FIG. 4d illustrates another embodiment in accordance with the present invention, in which a coated halogen incandescent lamp is used together with an aluminum reflector, that is, with a reflector which has no or only very little IR radiation transmissivity. Essentially the entire IR radiation is emitted forwardly, in highly diffuse manner, again effectively eliminating heat loading at the target area of the visible light cone.
The attached table illustrates comparative measurements of different reflector lamp in a simulated lamp holder, luminaire, or lighting fixture. The following lamps were used:
(1) An aluminum reflector (ALU), with an uncoated lamp, comparable to FIG. 4a.
(2) A cold-light reflector (KLR), with an uncoated lamp.
(3) A cold-light reflector (KLR), with a coated lamp.
(4) An interference filter reflector (IF), with an infra-red reflecting interference filter coated (IRC) lamp, see FIG. 4c, and using a cylindrical lamp bulb.
(5) An interference filter reflector (IF), with an infra-red reflecting interference filter coated (IRC) lamp, using an elliptical lamp bulb.
(6) An aluminum reflector (ALU), with an infra-red reflecting interference filter coated (IRC) lamp, see FIG. 4d.
In all the foregoing lamps, except item 5, the lamp had a cylindrical bulb.
The thermal loading of the lamp was determined in forward radiation direction by the temperature rise of a blackened wooden plate supplied with a thermal sensing arrangement, spaced from the reflector by 30 cm. The rearward heat loading was determined by the temperature rise of a simulated luminaire in form of a part-spherical metal housing (see FIG. 2).
The table clearly shows the different temperatures being measured in operation of the various lamps with the various reflectors and coatings, respectively.
The table also clearly shows that the influence of an infrared coating in a lamp having a cold-light mirror reflector (KLR lamp) has only a small influence on the radiation in forward direction. However, the influence of an infrared coating (IRC) on the lamp bulb when using aluminum-coated reflectors or a solid aluminum reflector is amazing. The temperature loading in forward direction drops from about 180° C. (item 1 of the table) to about 128° C. (item 6 of the table). The rearward radiation of an uncoated KLR (cold-light reflector or mirror lamp), item 2, drops from 173° C. to 123° C. or 125° C., respectively, when using the lamps of items 5 and 6 in the table.
Excellent effects are also obtained in forward direction of radiation. The lamp of item 4 has a forwardly directed radiation of 96° C., with a tolerable rearward radiation. This, already, is in the order of magnitude or prior art KLR lamps without, however, the effect of the prior art KLR lamps of the substantial rearward radiation which, previously, was above 170° C. (items 2, 3) and has now dropped to 134° C. (example 4) and even less if an elliptical lamp bulb is used. The best results in energy saving lamps are obtained with a shaped bulb (item 5), since the IR proportion of the overall radiation is inherently less than with a cylindrical bulb. In item 5, the IR loading in forward direction drops to about 86° C., whereas the loading on the luminaire or light fixture is entirely acceptable at 123° C. This loading is within the general loading temperature of luminaires without any measures being taken to reduce projected heat (item 1, rearward heat loading 112°; item 5, rearward heat loading 123°.
The reflector, if in form of a coated substrate, can be coated with various materials. Aluminum is inexpensive; silver is also suitable.
TABLE__________________________________________________________________________ Radiation in forward Backward radiation, direction, measured temperature increase of according to GermanReflector and type of lamp a simulated luminaire standad DIN VDE(with end closure 6) t in (°C.) t in (°C.)__________________________________________________________________________(1) ALU aluminum, uncoated 112 180 cylindrical bulb lamp(2) KLR cold-light mirror, 173 75 uncoated cylindrical bulb lamp(3) KLR cold-light mirror with 175 67 infrared coated cylindrical bulb(4) IF interference reflector 134 96 with infrared coated cylindrical lamp(5) IF interference reflector 123 86 with infrared coated elliptical lamp bulb(6) ALU aluminum reflector with 125 128 infrared coated cylindrical lamp__________________________________________________________________________ | To reduce heat loading of a luminaire or lamp fixture in which a halogen andescent lamp, retained in a reflector, is installed, the bulb of the halogen incandescent lamp is coated with a heat reflecting or mirror coating so that heat radiated from the filament (3) of the lamp (2, 10) is reflected from the surface of the bulb back into the bulb, rather than being directed from the filament to the reflector so that a portion of the radiation is diffusely transmitted from the lamp through an outer covering (6) thereof. If the reflector is only partially IR reflective, the remaining portion which can pass to heat the fixture or luminaire is small enough so that its temperature rise will be within an acceptable range. Thus, forwardly directed heat radiation is not focused, as is the visible light, and heat loading on an illuminated object is substantially reduced, without excessive heat loading of the fixture or luminaire. | 5 |
This is a continuation-in-part application of co-pending Ser. No. 06/886,233, filed July 16, 1986, now U.S. Pat. No. 4,738,026.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to electrical contacts and to a method and apparatus of making the same. More particularly the invention concerns a precision apparatus for making electrical contacts of the character having specially configured spaced apart tongues adapted to mate with plug connectors of standard design.
2. Description of the Prior Art
Various methods have been suggested in the past for the high volume manufacture of electrical contact members. In one common prior art method the contact members are stamped or lanced from a suitable piece of sheet material and the contact tongues formed or coined as necessary. Another method of making electrical contacts by one or more bending operations is described in British Pat. No. 836,397. Still another method, wherein the electrical contacts are made by splitting a bar of electrically conductive metal longitudinally over a portion of its length to form two contact tongues, is described in U.S. Pat. No. 4,040,177 issued to Beeler et al.
In one form of the aforementioned Beeler et al patent, a portion of the bar to be split is enclosed between two tools. The tools are then moved, sliding along each other perpendicular to the longitudinal dimension of the bar in mutually opposed directions, over a distance which is sufficient to produce the desired splitting. In another method of splitting, the bar to be split is retained over a part of its length such that one end is free, after which a wedge is longitudinally driven into the bar through this end.
Experience has shown that in order to repeatedly produce precision electrical contacts by a splitting or skieving method, it is absolutely essential that the portions of the material immediately adjacent the boundaries of the split or slice be rigidly and positively constrained. Only in this way can a predictable controlled shear split of the material be achieved. The recognition of this problem and its novel solution is at the very heart of the present invention As will be better appreciated from the discussion which follows, the unique apparatus of the present invention, which closely constrains the starting material along the boundaries of the skieve or split, overcomes the basic deficiencies of the prior art splitting methods, including the Beeler et al method, and for the first time permits the low cost, large volume manufacture of very high quality precision electrical contacts.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and apparatus for the precise manufacture of high quality electrical contacts by means of a closely controlled material skieving or splitting process. More particularly it is an object of the invention to provide an apparatus of novel design for use in making the precision electrical contacts wherein the starting material from which the electrical contacts are made is closely constrained in the area of the shear boundaries so that predictable and precisely controlled shearing of the material can repeatedly be achieved.
It is another object of the present invention to provide a method and apparatus for making electrical contacts of the aforementioned character in which material waste is minimized and manufacturing costs are kept at an absolute minimum.
Another object of the invention is to provide an apparatus of the character described in the preceding paragraphs which is of a simple straightforward design requiring a minimum amount of maintenance.
Still another object of the invention is to provide a method and apparatus of the character described which is easy to use by untrained workmen and is readily susceptible of automating to accomplish very high volume production rates.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generally perspective view of one form of the apparatus of the invention for forming electrical contacts.
FIG. 2 is an enlarged cross-sectional view taken along lines 2--2 of FIG. 1.
FIG. 3 is an exploded view of the apparatus for making electrical contacts in accordance with the method of the invention.
FIG. 4 is a fragmentary view of the rough form electrical contact made in accordance with the method of the invention.
FIG. 5 is a cross-sectional view taken along lines 5--5 of FIG. 4.
FIG. 6 is a fragmentary side elevational view of the electrical contact after blanking, coining and pre-forming.
FIG. 7 is a front view of the electrical contact further showing the configuration of the contact after coining and pre-forming.
FIG. 8 is a front view of the electrical contact made in accordance with the method of the present invention after final forming over a mandrel or the like.
FIG. 9 is a fragmentary perspective view of the form of punch used in connection wit a apparatus of the invention shown in FIGS. 1 through 3.
FIG. 10 is a side elevational, cross-sectional fragmentary view of an alternate form of the apparatus of the invention embodying a die similar to that illustrated in FIG. 1. This form of the apparatus of the invention makes use of a slightly different punch and is used in forming the electrical contact by skieving the material held captive within the die.
FIG. 11 is an exploded view similar to FIG. 3 showing the appearance of a rough form electrical contact after having been formed using the form of the apparatus of the invention illustrated in FIGS. 9 and 10.
FIG. 12 is a side view, partly in section, of the rough form electrical contact made by the skieving method using the apparatus of FIGS. 9 and 10.
FIG. 13 is an exploded view of an alternate form of the apparatus of the invention capable of simultaneously forming a plurality of electrical contacts.
FIG. 14 is an enlarged fragmentary, generally diagrammatic view of the workpiece following formation of the rough contacts.
FIG. 15 is a generally schematic view illustrating an alternate form of splitting punch moving into initial contact with the work material, which work material is clamped securely within the clamping die of the apparatus.
FIG. 16 is a fragmentary view partially in cross-section taken along lines 14--14 of FIG. 13.
FIG. 17 is a generally schematic view illustrating the progressive splitting movement of the splitting punch as it advances relative to the workpiece and splits the workpiece substantially along the centerline thereof.
FIG. 18 is a cross-sectional view taken along lines 18--18 of FIG. 17.
FIG. 19 is a generally diagrammatic view comparing the prior art method of removing the slug portion of the work material with the removal of the slug portion in accordance with the present invention.
FIG. 20 is an enlarged generally diagrammatic view further illustrating the slug removal step.
FIG. 21 is fragmentary top view of the finished electrical contact formed by an alternate form of the method of the present invention.
FIG. 22 is a side elevational view taken along lines 22--22 of FIG. 21.
FIG. 23 is a fragmentary plan view of another form of splitting punch having concave shearing faces.
FIG. 24 is a view taken along lines 24--24 of FIG. 23.
FIG. 25 is a fragmentary plan view of a rough contact made using the punch illustrated in FIG. 23.
FIG. 26 is a view taken along lines 26--26 of FIG. 25.
FIG. 27 is a fragmentary plan view of another form of splitting punch having convex shearing faces.
FIG. 28 is a view taken along lines 28--28 of FIG. 27.
FIG. 29 is a fragmentary plan view of a rough contact made using the punch illustrated in FIG. 27.
FIG. 30 is a view taken along lines 30--30 of FIG. 29.
DESCRIPTION OF THE INVENTION
Referring to the drawings, and particularly to FIGS. 1, 2 and 3, one form of the apparatus for making an electrical contact member from a generally planar shaped workpiece of electrically conductive material is generally designated by the numeral 12. As best seen in FIG. 3, the starting material, or workpiece "W", used in the practice of the method of the present invention has first and second generally parallel faces 14 and 16 of a predetermined area terminating in a perpendicularly extending third face, or edge, 18 of a predetermined width.
The apparatus 12 comprises a die portion including a supporting body 20 having a first, or front, face 22, a second, or top, face 24 and a bottom face 26 adapted to rest on a generally planar, rectangular base 28. A vertically extending, generally "U" shaped punch receiving channel 30 is formed in body member 20. As best seen in FIG. 3, channel 30 is defined by transversely spaced, generally parallel side walls 32 and 34 which join with a perpendicularly extending back, or end, wall 36.
Closely receivable within the lower potion of channel 30 are workpiece supporting means for continuously rigidly supporting the first and second faces 14 and 16 of the workpiece "W". In the form of the invention illustrated in FIGS. 1 through 3, the workpiece supporting means comprises supporting elements 40 and 42. Elements 40 and 42 support the entire face 14 and 16 of the workpiece save in the areas "A" and "B" which correspond to the cross-sectional area of transverse grooves 44 and 46 formed in the elements 40 and 42. Similarly, in the second form of the apparatus of the invention illustrated in FIG. 11, the workpiece supporting means support the first and second faces of the workpiece throughout the entire area of the first and second faces save for an area designated by the letter "C" in FIG. 11. Area "C" on face 14 of the workpiece "W" is of a predetermined width and length corresponding to the width and length of groove 44 formed in element 40. As indicated in FIG. 11 this first unsupported area extends downwardly from the third face, or edge, 18 of the workpiece "W".
It is to be observed that in both the first and second forms of the apparatus of the invention, supporting element 40 is provided with a transversely extending channel 44 therethrough, which channel has a cross-sectional area substantially corresponding to the previously identified unsupported areas "A" and "C". As seen in FIGS. 3 and 11, channel 44 is defined by spaced apart parallel walls 44a and 44b which join with a perpendicularly extending bottom wall 44c.
In the first form of the apparatus of the invention shown in FIGS. 1 through 3, supporting element 42 is also provided with a transversely extending channel 46 which is defined by downwardly extending spaced apart parallel side walls 46a and 46b which join with in a perpendicularly extending bottom wall 46c. As indicated in FIG. 3, the cross-sectional area of channel 46 is equal to unsupported area "B" on face 16 of the workpiece "W". In the discussion which follows, it will become apparent that areas "A" and "B" are equal to the sheared areas, or tongues, formed in the workpiece depicted in FIG. 3, while area "C" is equal to the area of the skieved, or tongue, portion formed in the workpiece shown in FIG. 11 and identified therein by the numeral 49.
Referring particularly to FIG. 11, it is to be noted that the second supporting element, designated in this figure by the numeral 42a, does not have a transversely extending channel formed therein. Rather, the entire front face "F" of supporting element 42a provides support to the entire second, or rear, face 16 of the workpiece "W".
Turning again to FIGS. 1 through 3, the apparatus of the form of the invention thereshown further includes shearing, or punch, means closely receivable within channel 30 of the supporting body 20 for reciprocal movement therewithin. The function of the shearing means is to impart a hearing force to the third face, or edge, 18 of the workpiece "W" at a location intermediate the first and second faces 14 and 16. The shearing means, shown here as punch 50, includes interconnected side walls 52 which terminate in a upper wall 54 and a lower wall 56. As best seen by also referring to FIG. 9, extending downwardly or outwardly from end wall 56 of the punch 50 is a cutter element 58 which has the shape of an isosceles triangle in longitudinal cross-section with the apex thereof terminating in a cutting edge 60. As indicated in FIG. 1, punch 50 is closely receivable within channel 30 of body 20 and is controllably movable downwardly in the direction of the arrow of FIG. 1.
In both forms of the apparatus of the invention shown in the drawings, the workpiece clamping or supporting elements 42 and 44 are provided with opposing faces adapted to be brought into pressural engagement with faces 14 and 16 respectively of the workpiece. The supporting or clamping elements 40 and 42 are maintained in pressural engagement with the faces of the workpiece "W" by means of a plurality of stacked bars 64 which are interconnected with face 22 of body 20. As best seen in FIGS. 3 and 10, each of the bars 64 is provided with spaced apart apertures 66 which receive threaded connectors 68, which connectors are threadably received within internally threaded apertures 70 formed in the forward face 22 of body 20. As indicated in FIG. 1, with stacked bars 64 securely affixed to supporting body 20 in the manner shown, punch 50 is closely receivable within an area defined by the rear face of stacked bars 64 and the side and end walls 34 and 36 of channel 30.
Turning once again to FIG. 10, wherein a second form of the apparatus of the invention is shown, the punch, there designated by the numeral 50a, is of similar construction to punch 50 having a lower end wall 56a. Extending outwardly or downwardly from end wall 56a is a cutter element of slightly different configuration from that shown in FIGS. 3 and 9. More particularly, this cutter element, designated by the numeral 58a, has the longitudinal cross-sectional shape of a right triangle terminating at its apex in a cutting edge 60a. As will presently be discussed, the apparatus of the second form of the invention shown in FIGS. 10 and 11 is used in skieving, or slicing, the workpiece "W" in a predeterminable controlled manner to form a tongue 62 (FIG. 11).
In practicing the method of the invention using the apparatus of the form of the invention shown in FIGS. 1 through 3, after the clamping bars 64 are removed from the face of the die body 20 supporting element 42 is inserted into the lower portion of "U" shaped channel 30 with its base resting on base 28. The workpiece "W" is next inserted into the "U" shaped channel with face 16 thereof in surface contact with the outwardly extending face of supporting element 42. With the workpiece in place, supporting element 40 is then inserted into channel 30 of the die body so that the rear face thereof is in intimate contact with the front face 14 of the workpiece "W". Next, the clamping bars 64 are interconnected with the front face 22 of the die body 20 by means of threaded connectors 68 so as to securely clamp the workpiece between elements 40 and 42. It is important to note that with the workpiece clamped in the die in the manner thus described, the first and second faces of the workpiece are firmly and securely supported throughout the entire area of their opposing faces save for the first unsupported area "A" and the second unsupported area "B" (FIG. 3) which are co-extensive with the cross-sectional areas of transversely extending grooves 44 and 46 formed in supporting elements 40 and 42.
With the workpiece supported within the die in the manner described in the preceding paragraphs, the punch 50 is then inserted into the channel defined by the rear faces of clamping bars 64 and the faces of the "U" shaped channel 30 formed in die body 20. In the embodiment of the invention shown in FIGS. 1 through 3, the cutting portion 58 of the punch 50, which is in the cross-sectional shape of an isosceles triangle, contacts the workpiece "W" so that the cutting edge 60 precisely bisects the upper edge portion 18 of the workpiece. A downward force exerted on the punch 50 in the direction of the arrow in FIG. 1 will cause the workpiece to be sheared in the manner shown in FIGS. 2 and 3 forming angularly diverging tongues 75 and 77. After shearing, tongue 75 will have an area precisely equal to the area "A which, as previously noted, is equal to the cross-sectional area of groove 44. Similarly, tongue 77 will have an area "B" which is precisely equal in area to the cross-sectional area of groove 46 formed in support element 42.
An important aspect of the present invention resides in the fact that because the workpiece "W" is rigidly clamped between supporting elements 40 and 42 with faces 14 and 16 being supported throughout their entire areas, save for the areas "A" and "B", the downward force of the punch 50 effects a true shearing action of the unsupported areas "A" and "B" along side shearlines which are coextensive with the transversely spaced edges of the grooves 44 and 46 respectively. This positive support of the workpieces immediately adjacent the shearlines of areas "A" and "B" permits a degree of precise repeatability which is not possible with prior art devices presently in use.
Turning now to FIGS. 10 and 11, the apparatus of this form of the invention is used to controllably skieve a layer of the workpiece "W" to form a tongue having a predetermined precisely controlled width and length. As indicated in FIG. 10, the support elements 40 and 42a are supported within in die body 20 in the same manner as previously discussed herein. However, in this form of the invention, support element 42a provides support to the entire rear face 16 of the workpiece, while support element 40 provides support to the face 14 of the workpiece "W" throughout its entire area, save the unsupported area designated in FIG. 11 by the letter "C". As previously mentioned, this unsupported area is coextensive with the cross-sectional area of the groove 44 formed in support element 40.
In addition to the different manner in which the workpiece "W" is supported in the apparatus of the second form of the invention, it is to be noted that punch 50a is also of a different configuration. More particularly, the cutting element of punch 50a, while in the shape of a triangle in longitudinal cross-section, takes the shape of a right triangle, rather than an isosceles triangle, with the apex of the triangle forming the cutting edge 60a.
Once the workpiece "W" is securely clamped between clamping elements 40 and 42a, a downward pressure on punch 50a in the direction of the arrow in FIG. 10 will bring the cutting edge 60a into contact with the upper edge 18 of the workpiece "W" at a precisely determined location intermediate faces 14 and 16 of the workpiece. A continued downward force on punch 50a will cause the controllable skieving of a layer of material having an area "C", which area is coextensive with the cross-sectional area of the groove 44 formed in clamping element 40. Once again, because the entire are of faces 14 and 16 of the workpiece are positively supported, save for the area designated by the letter "C", a downward movement of the punch 50a will cause a precise skieving of a layer of material of predetermined thickness to form a tongue of the character designated by the numeral 49 in FIG. 11. This precise skieving of the material can be reproduced time after time because of the rigid support and positive constraint of the workpieces in the immediate proximity of the shearline defined by the edges of groove 44 in element 40.
Following the shearing, or skieving, of the workpiece in the manner described in the preceding paragraphs, the electrical contact is finished in the manner illustrated in FIGS. 4 through 8. Referring particularly to FIGS. 4 and 5, after shearing the workpiece "W" using the apparatus of FIGS. 1, 2 and 3, the rough electrical contact thus formed has angularly diverging tongues 75 and 77 each having a thickness of one-half the thickness of the workpiece "W". Following the shearing step, the workpiece is removed from the die, the tongues 75 and 77 are bent into a closed position and the contact is blanked to the desired contour as, for example, that shown in FIG. 6. Next the tongues 75 and 77 are, once again, spread apart and the contact is coined and pre-formed into the desired configuration as for example that shown in FIG. 7. Finally, as a last step in forming the electrical contact, the contact of the configuration shown in FIG. 7 is bent into final form over a mandrel, or the like, to form the contact in a final configuration as, for example, that shown in FIG. 8.
Referring now to FIG. 12, it is to be understood that the rough electrical contact thereshown was formed by the skieving method using the apparatus illustrated in FIGS. 10 and 11.
This electrical contact includes an outwardly extending tongue 79 having a thickness approximately equal to one-half the thickness of the starting workpiece "W". The rough electrical contact of the configuration illustrated in FIG. 12 is prefinished into the desired final configuration in the same general manner as previously discussed in connection with the finishing of the contact depicted in FIG. 5.
It should be appreciated that the apparatus shown in the drawing is, for sake of simplicity, depicted as a single punch and die acting upon a single discrete workpiece "W". In the actual commercial practice of the method of the invention, the apparatus would be mechanized so that a continuous length of starting material would be fed through an automated punch and die apparatus to continuously shear or skieve the material to form rough contacts which would then be configured and formed into end product electrical contacts on a continuous basis. However, because the production apparatus forms no part of the present invention, the details thereof are neither shown in the drawings, nor described herein.
It should also be observed that the configuration of the electrical contacts as shown in FIGS. 4 through 8 and 12 are exemplary only. The apparatus of the invention can be used to produce electrical contacts having a wide variety of tongue shapes and thicknesses depending upon the end use to be made of the contacts.
Turning now to FIGS. 13 and 14, an alternate approach to the shearing tool design and workpiece shearing operation of the present invention is there illustrated. The apparatus shown in FIG. 13 is somewhat similar to that shown in FIGS. 1, 2 and 3 and like numerals are used in FIG. 13 to identify like components. Unlike the apparatus earlier described, the apparatus shown in FIG. 13 is capable of simultaneously forming a plurality of electrical contacts rather than one. As in the previously described embodiment, the starting material or workpiece "W", used in the practice of the method of the present invention, has first and second generally parallel faces 14 and 16 of a predetermined area terminating in a perpendicularly extending third face, or edge, 18 of a predetermined width.
The apparatus 80 comprises a die portion including a supporting body 20 having a first, or front, face 22, a second, or top, face 24 and a bottom face 26 adapted to rest on a generally planar, rectangular base 28. A vertically extending, generally "U" shaped punch receiving channel 30 is defined by transversely spaced, generally parallel side walls 32 and 34 which join with a perpendicularly extending back, or end, wall 36.
Closely receivable within the lower portion of channel 30 are workpiece supporting means for continuously supporting the first and second faces 14 and 16 of the workpiece "W". In the form of the invention illustrated in FIG. 13 the workpiece supporting means comprises supporting elements 82 and 83. Elements 82 and 83 support substantially the entire faces 14 and 16 of the workpiece save in the areas which correspond to the cross-sectional area of transverse grooves "X" formed in the elements 82 and 83.
It is to be observed that supporting element 82 is provided with transversely extending channels CH therethrough, which channels each have a cross-sectional area substantially equal to the unsupported areas "A" on workpiece "W". Each channel CH is defined by spaced apart parallel walls which join with a perpendicularly extending bottom wall.
Supporting element 83 is also provided with transversely extending channels CH, each of which is defined by downwardly extending spaced apart parallel side walls which join with in a perpendicularly extending bottom wall. The cross-sectional area of these channels is substantially equal to the unsupported areas "B" on face 16 of the workpiece "W". Areas "A" and "B" are equal to the sheared areas, or tongues, simultaneously formed in the workpiece depicted in FIG. 14.
Turning again to FIG. 13, the apparatus of the form of the invention thereshown further includes shearing, or punch, means closely receivable within channel 30 of the supporting body 20 for reciprocal movement therewithin. The function of the shearing means is to impart shearing forces to the third face, or edge, 18 of the workpiece "W" at locations intermediate the first and second faces 14 and 16. The shearing means, shown here as punch 84, includes interconnected side walls 84a which terminate in an upper wall 84b and a lower wall 84c. Extending downwardly or outwardly from end wall 84c of the punch 84 are cutter elements 86 each of which has the general shape of an isosceles triangle in longitudinal cross-section with the apex thereof terminating in a cutting edge 88. As indicated in FIG. 13, punch 84 is closely receivable within channel 30 of body 20 and is controllably movable in a downwardly direction.
As in the earlier forms of the apparatus of the invention shown in the drawings, the workpiece clamping or supporting elements 82 and 83 are provided with opposing faces adapted to be brought into pressural engagement with faces 14 and 16 respectively of the workpiece. The supporting or clamping elements 82 and 83 are maintained in pressural engagement with the faces of the workpiece "W" by means of a plurality of stacked bars 64 which are interconnected with face 22 of body 20. Each of the bars 64 is provided with spaced apart apertures 66 which receive threaded connectors 68, which connectors are threadably received within internally threaded apertures 70 formed in the forward face 22 of body 20. With stacked bars 64 securely affixed to supporting body 20, punch 84 is closely receivable within an area defined by the rear face of stacked bars 64 and the side and end walls 34 and 36 of channel 30.
Practice of the method of the invention using the apparatus of the form of the invention shown in FIGS. 13, is substantially as previously described herein. However, with the configuration of the apparatus shown in FIG. 13, three pairs of tongues 89 of the general character illustrated in FIG. 14, will simultaneously be formed. Due to the novel character of the method and apparatus of the present invention, the spacing between the centerlines of tongues 89 can be closely controlled. The apparatus is readily adaptable to enable high volume fabrication of strips of contacts having conventional 0.100 inch and 0.050 inch centers. Additionally, for the first time, fork style contacts of of given thicknesses can be produced on very small center distances ranging down to about 0.010 inches. This has substantial economic advantages in that meaningful material savings can be realized, and also for the first time, an integral comb, or strip, of contacts on extremely small center distances can be formed and assembled into a connector housing as a unit rather than as individual contacts, as is typical in the prior art.
Turning now to FIG. 15, a shearing punch, generally identified by the numeral 90, can be seen to be of a different design than the earlier described elements. The punch 90 is provided with a body portion 90a having inwardly tapering side walls 90b and a workpiece engaging portion 90c also having inwardly tapering walls identified as 90d which walls converge to form an apex 90e. Apex 90e forms the cutting edge of the punch and is preferably somewhat rounded rather than being a sharp edge. As will be discussed in greater detail hereinafter, by judiciously selecting a predetermined included angle "Z" of on the order of sixty degrees, several unique and unexpected results are achieved during the shearing operation. One of these results, which is extremely important in the forming of electrical contacts, is an unexpected burnishing effect which automatically produces a highly polished contact surface as the workpiece is controllably sheared. Another unexpected result is the progressive increase in thickness of the tongue portions during the shearing process so that the finished tongues have an average thickness greater than one half the thickness of the starting workpiece. Still another unexpected result of the shearing operation is the overall shortening of the length of the tongue portions with respect to the length of the unsupported areas of the workpiece. These surprising results will be discussed in greater detail hereinafter.
As was the case in the shearing operation shown in FIG. 2, and as indicated in FIGS. 15 and 16, the workpiece W is closely supported by supporting, or clamping, means comprising clamping elements 92 and 94. As previously discussed, these important clamping elements support the faces of the workpiece as the splitting tool, or punch element, advances in the manner shown in FIG. 17. As pointed out in connection with the previously described embodiments of the invention, this support of the opposing faces of the workpiece in the areas proximate the material shear is of substantial importance to the accomplishment of the method of the invention and to the production of electrical contacts having the unusual configuration described in the preceding paragraph. Experimentation has shown that, while very small clearances between the workpiece and the clamping means is possible, the quality of the contacts produced tends to degrade.
Referring particularly to FIG. 17 of the drawings, there is illustrated, by way of example, the shearing of a phosphor bronze workpiece W in accordance with the method of the instant embodiment of the invention. As shown in the upper portion of FIG. 17, the workpiece W, which has a thickness of about 0.025 inches, or 2 T, is being initially penetrated by the punch 90. At the point designated "A", the punch 90 has entered the workpiece approximately 0.011 inch and, as shown in the drawings, has created a "plowing" like effect on the material. As the punch 90 continues downwardly toward point "B" with sufficient force to evenly shear, but not tear, the material, substantial pre-shear compressive forces are continuously exerted on the workpiece at locations proximate the apex of the punch. The imposition of these very high, pre-shear compressive forces causes the unexpected burnishing effect to occur on either side of the apex of the punch. It is this burnishing action which results in the formation of a remarkably fine finish on the sheared surfaces of the electrical contact. It is to be appreciated that as the punch moves downwardly shearing occurs simultaneously along five shear lines and, as a result, six surfaces are simultaneously created. These six surfaces are the inner surface of each tongue and the transversely spaced outer edges of each tongue.
By the time the cutter element, or punch, 90 has moved to point "C", it has generally bisected the workpiece to a depth of about 0.091 inches and the angularly diverging tongues of the contact are beginning to take shape. Continued movement of the punch to point "D" which, in the example shown in FIG. 17, represents a depth of on the order of 0.191 inches, results in the formation of the elongated angularly diverging tongues identified by the numeral 97. Examination of the inner surfaces of these tongues reveals the existence of a highly polished, very fine finish along their entire length. Examination of the tongues also reveals that they have become progressively thicker and that, if they were to be bent inwardly toward one another, their overall length would be less than the length of the unsupported area of the starting workpiece. The apparent reasons for this thickening of the tongue walls as well as the foreshortening effect will presently be discussed.
Turning now to FIG. 18, which is a cross-sectional view of tongue 97 taken along lines 18--18 of FIG. 17, the thickness T1 of the tongue in the present example is on the order of 0.0153 inches. In light of the fact that the starting thickness 2T of the workpiece was on the order of 0.025 inches and one-half this thickness, or T, was on the order of 0.0125 inches, it is apparent that a marked increase in wall thickness has occurred during the formation of tongue 97.
Experience has shown that for the same starting material, the smaller the angle "Z" formed on the punch the smaller will be the pre-shear compressive forces generated and the smaller will be the increase in average thickness of the angularly diverging tongues. Depending upon the character of the starting material, a reduction in the size of angle "Z" will also result in a more moderate curling of the diverging tongues. Accordingly, it is to be understood that tongue configuration can be precisely controlled by choice of materials, and by changing the angle "Z" formed on the punch. Additionally, the length of the tongues can be controlled by controlling the depth of travel of the punch 90. For example, longer tongues 97a can be formed as a result of further downward travel of the punch to a point "E" (FIG. 17). However, experimentation has revealed that, with most starting materials, after a certain depth of penetration of the punch has been reached, the thickness of the tongues will stabilize and will not further increase in thickness.
It is to be understood that the results described in the preceding paragraphs vary somewhat depending upon the character of the starting material. As a general rule, however, the softer the starting material and the more obtuse the shearing punch angle, the greater will be the thickening of the tongues and the greater will be their foreshortening. The reverse is true when harder starting materials and sharper shearing punch angles are employed. The table which follows illustrates these results (thicknesses and lengths are expressed in inches and punch angle is expressed in degrees).
__________________________________________________________________________ THICKNESSSAMPLE TEMPER OF PUNCH STARTING TONGUE TONGUENO. MATERIAL MATERIAL ANGLE LENGTH LENGTH THICKNESS__________________________________________________________________________1 CA260 0.025 40 0.345 0.270 0.017 annealed brass2 CA260 0.025 50 0.345 0.2485 0.0183 annealed brass3 CA260 0.025 60 0.345 0.2295 0.020 annealed brass4 CA260 0.025 40 0.345 0.295 0.0156 3/4 hard5 CA260 0.025 50 0.345 0.2735 0.0158 3/4 hard6 CA260 0.025 60 0.345 0.255 0.0719 3/4 hard7 CA510 0.025 40 0.345 0.3015 0.0145 1/2 hard phosphor/ bronze8 CA510 0.025 50 0.345 0.286 0.0152 1/2 hard phosphor/ bronze9 CA510 0.025 60 0.345 0.273 0.0158 1/2 hard phosphor/ bronze10 CA510 0.025 40 0.345 0.305 0.0148 3/4 hard11 CA510 0.025 50 0.345 0.290 0.0156 3/4 hard12 CA510 0.025 60 0.345 0.280 0.0162 3/4 hard13 CA510 0.025 40 0.345 0.3155 0.0143 full hard14 CA510 0.025 50 0.345 0.2995 0.0148 full hard15 CA510 0.025 60 0.345 0.295 0.0155 full hard16 CA510 0.020 50 0.345 0.3095 0.0115 full hard17 CA510 0.020 60 0.345 0.2995 0.0118 full hard__________________________________________________________________________
Turning to FIGS. 19 and 20, the present method of slug removal is compared with a typical prior art slug removal step. As shown in FIG. 19, which illustrates the prior art conditions, the slug, or adjacent part, is identified by the numeral 100, the blank punch is indicated by the numeral 102 and the starting material is identified by the numeral 104. Referring to the left hand portion of FIG. 19 the interference between the slug 102 and the blank 104 is at once apparent. If pressure is exerted in the direction of the arrow 105 on the slug knockout punch 106 the interference between the slug and the blank resists removal of the slug. Accordingly, in the prior art the slug 100 is normally removed in the opposite direction as indicated in the right hand portion of FIG. 19.
Turning to FIG. 20 which illustrates slug removal in accordance with the method of the present invention, the slug, or adjacent part, is identified by the numeral 108, the blanks by the numeral 110 and the starting material by the numeral 112. In light of the highly burnished surfaces formed on the electrical contacts due to the shearing by the present method of the invention, slug removal takes on greater significance since it is highly desirable that the highly polished surfaces be carefully preserved. As shown in the right hand portion of FIG. 20, the punch 90 has sheared the starting material in a unique manner such that the tongues 110 conform, not to the die, but rather to the width of the punch. This unexpected and unusual phenomenon of the sheared material conforming to the shape of the punch rather than to the die, will be discussed in greater detail hereinafter. Suffice to point out at this time, that this conformation permits ready removal of the slug in the manner shown in the left hand portion of FIG. 20. Because of the clearance, which results, the knock out punch 114 can more easily remove the slug, or adjacent part, in the same direction as the travel of the die and indicated by the arrows. Similarly, the sheared tongues can be readily removed from the die, without damage.
Referring now to FIGS. 21 and 22, a contact forming step is there illustrated. As previously discussed, and as shown in FIG. 17, as the punch advances the angularly diverging tongues of the contact will be formed. The converged configuration of the tongues naturally results and, as earlier stated, can be controlled to some degree by varying the angle "Z" of the punch. Accordingly, the method of the present invention makes it possible to produce electrical contacts in a desired final configuration by merely exerting controlled bending pressures on the diverging tongues using forming dies of the character shown in FIG. 22 and designated therein by the numeral 116. By exerting inwardly directed pressures on the specially configured dies 116 the tongues 97a of the contact can be formed from the as sheared configuration generally illustrate by the phantom lines into the desired final configuration illustrated by the solid lines. This method of forming the contact in its final configuration also tends to further preserve the highly polished surfaces of the contact which have been automatically formed during the shearing step.
Turning now to FIGS. 23 through 26, the novel feature of the invention, namely the conformation of the tongues to the punch, is further illustrated. As discussed in the preceding paragraphs, with the opposing surfaces of the workpiece substantially supported throughout their entire area, save for an unsupported area of the desired size and configuration, the method of the present invention permits the formation of contacts having tongues which closely correspond to the configuration of the punch of the shearing apparatus. This feature of the invention not only permits the forming of contact tongues having a width less than the width of the unsupported area of the workpiece, but also permits the forming of contact tongues of various cross-sectional configurations.
As indicated in FIG. 23, the punch P of the apparatus of the invention can be formed such that the angularly extending shearing faces P-1 and P-2 of the punch are generally concave. When this type punch is used in connection with a die of the character illustrated in FIG. 1, contacts having tongues 120 with concave surfaces of the character illustrated in FIGS. 25 and 26, can be formed.
Turning to FIGS. 27 through 30, the punch P of the apparatus of the invention can be formed such that the angularly extending shearing faces P-2 and P-4 of the punch are generally convex. When this type of punch is used with dies of the character shown in FIG. 1, contacts having tongues 122 with convex surfaces of the character illustrated in FIGS. 29 and 30, can be formed. In either case tongues having a highly polished inner surface are automatically produced.
It is apparent that the formation of high quality electrical contacts having tongues of various cross-sectional configurations, as for example concave or convex, has great commercial advantage. In applications where the pin with which the electrical contact is to mate is preferably cylindrical in shape, contacts having concave surfaces as illustrated in FIG. 25, can be expeditiously formed to closely mate with the cylindrical pin. Conversely if the pin with which the contact is to mate is of a dished out configuration, contacts having the configuration shown in FIG. 29 can be formed. In a similar manner, a contact can be formed to mate with virtually any shaped pin by simply designing the punch of the apparatus accordingly.
It is to be understood that the method and apparatus of the invention, as previously described herein, can be used to manufacture a wide variety of useful devices. Such devices include; end products such as electrical contacts, thermal contacts, fasteners of various kinds, and similar types of hardware, as well as interim configurations of these products. When electrical contacts are to be fabricated, the starting material is, of course, electrically conductive. On the other hand, when thermal contacts, such as may be used in heat dissipation systems, ar to be fabricated, thermally conductive material is used as the starting material. For other types of hardware devices, end product use will govern the choice of starting material.
Having now described the invention in detail in accordance with the requirements of the patent statutes, those skilled in this art will have no difficulty in making changes and modifications in the individual parts or their relative assembly in order to meet specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims. | A precision apparatus for controllably shearing a thin workpiece of material to make devices such as electrical contacts of the character having specially configured spaced apart tongues adapted to mate with plug connectors of standard design. The apparatus is designed to rigidly support the workpiece except in the precise area of the shear during the entire shearing step. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus comprising a hopper and an auger conveyor for conveying solid items, such as an apparatus for the production of ice cream mass with solid ingredients.
BACKGROUND OF THE INVENTION
[0002] In the production of frozen ice cream mass with solid ingredients, it is well-known to use an auger conveyor for conveying the solid ingredients from a hopper to a pump, which may for instance be a lamella pump or a piston pump, by means of which the solid ingredients are mixed into a flow of ice cream mass.
[0003] It is also known to use auger conveyors having augers with increasing pitch and/or decreasing core diameter along the direction of conveyance. This results in an increasing volume along the auger, which assures that the amount of solid ingredients entering the auger conveyor is more evenly distributed across the hopper, whereas an auger with a constant pitch and core diameter will typically be filled up shortly after its starting point, meaning that almost no ingredients will be drawn from the other side of the hopper.
[0004] However, even with such measures having been taken, it has proven to be difficult to avoid clogging and lumping of the ingredients and damage to fragile types of ingredients, especially at the outlet from the hopper to the auger conveyor, which in turn results in an uneven dosing of the ingredients at the end of the auger conveyor.
BRIEF DESCRIPTION OF THE INVENTION
[0005] It is an object of the present invention to provide a solution to this problem by providing an apparatus with a substantial reduction of the clogging and lumping of the ingredients and of the damage to fragile types of ingredients, thus resulting in a substantial improvement of the evenness of the dosing of solid ingredients from the auger conveyor, the ingredients falling from the conveyor in a free flow and in small portions.
[0006] The present invention relates to an apparatus comprising a hopper and an auger conveyor for conveying solid items, wherein the auger conveyor comprises an auger and an outlet pipe enclosing the auger along at least a part of the length of the auger, the outlet pipe having an inlet end and an outlet end, wherein the outlet pipe is mounted at its inlet end to the hopper for receiving solid items from the hopper through an outlet opening near the bottom of the hopper, and the auger extends partly along at least a part of the bottom of the hopper, partly inside the outlet pipe along substantially the full length thereof, and wherein at least a part of the inner surface of the hopper above the outlet opening is inclined towards the direction of conveyance of the auger conveyor.
[0007] Letting a part of the inner surface above the outlet opening incline like described above substantially reduces the risk of solid items being stuck, squeezed and/or damaged at the upper edge of the outlet opening. Especially for fragile items such as some solid ingredients to be mixed into an ice cream mass, this configuration of the inner surface of the hopper significantly reduces the amount of items being stuck and/or crushed when entering the outlet pipe from the hopper.
[0008] It should be noted that in the present document, the word “solid” used in expressions like “solid items” and “solid ingredient” is meant to include viscous substances like for instance jams or marmalades, which may not be categorised as “solids” in other contexts.
[0009] In an embodiment of the invention, said inclined part of the inner surface of the hopper forms an angle with respect to the vertical in the range from 20° to 88°, preferably in the range from 45° to 85°, most preferably in the range from 55° to 75°.
[0010] Angles within these ranges have proved to result in the largest reduction of the amount of solid items getting stuck and/or crushed when entering the outlet pipe from the hopper.
[0011] In an embodiment of the invention, the pitch of the auger increases, gradually or stepwise, along the direction of conveyance of the auger conveyor.
[0012] In a further embodiment of the invention, the most significant increase of the pitch of the auger takes place at a point just inside an outlet channel of the hopper.
[0013] In an embodiment of the invention, the auger comprises a central core from which one or more helical screw flights extend, and the diameter of the core decreases, gradually or stepwise, along the direction of conveyance of the auger conveyor.
[0014] In a further embodiment of the invention, the most significant decrease of the diameter of the central core of the auger takes place at a point just inside an outlet of the hopper.
[0015] Within the hopper, the use of augers with increasing pitch and/or decreasing core diameter along the direction of conveyance results in the amount of solid ingredients entering the auger conveyor being more evenly distributed across the hopper. Within the outlet pipe, the use of an increasing pitch and/or a decreasing core diameter is also advantageous because it results in an increasing volume available for conveyance of the solid ingredients without introduction of any more solid ingredients. This contributes to loosing up any lumps or tendencies to clogging of the ingredients and in turn results in a more even dosing of the ingredients at the end of the auger conveyor. In the outlet channel of the hopper, an increasing volume is especially important in order to avoid clogging or squeezing of the ingredients entering the outlet pipe from the hopper. Therefore, it is advantageous to let the pitch increase and/or to let the diameter of the core decrease extra much at this location.
[0016] In an embodiment of the invention, at least along a part of the length of the outlet pipe enclosing the auger, the cross-sectional outline of the inner side of the outlet pipe is a circular shape being superposed by a plurality of undulations.
[0017] The use of outlet pipes with such undulations has proved to result in less damage of the solid ingredients during conveyance through the outlet pipe because the solid ingredients are pushed more gently towards the outlet end of the outlet pipe, and in the breaking up of lumps of solid ingredients rather than formation of lumps due to solid ingredients being pressed together.
[0018] This seems to be due to at least two features of the undulations. Firstly, the increasing volume around the auger without introduction of any more solid ingredients helps loosing up any lumps or tendencies to clogging of the ingredients. Secondly, the parts of the undulations extending towards the centre of the outlet pipe function as guides helping to “arrange” the solid ingredients in a proper way so that they are more easily being conveyed through the outlet pipes without being rotated with the auger.
[0019] Thus, the use of such outlet pipes has proved to result in substantially less clogging and lumping of the ingredients and damage to fragile ingredients, which in turn reduces the variation in the dosing of solid ingredients from the auger conveyor over time, the variation being represented by the standard deviation of the dosing flow delivered by the auger conveyor and measured as weight unit per time unit.
[0020] In an embodiment of the invention, the undulations extend parallel to the longitudinal direction of the outlet pipe.
[0021] In an embodiment of the invention, the undulations are equally spaced around the outlet pipe.
[0022] In an embodiment of the invention, the undulations are sinusoidal.
[0023] For production purposes, it is convenient to make the outlet pipes with undulations that extend parallel to the longitudinal direction of the pipe and, equally spaced and of sinusoidal shape, although similar results may be obtained as well with undulations constructed otherwise, such as with sharp edges or by arranging profiles on the inner side of a larger, cylindrical pipe, for instance by welding.
[0024] In an embodiment of the invention, the number of undulations is in the range from 2 to 20, preferably in the range from 6 to 12, most preferably in the range from 7 to 9.
[0025] Numerous tests have proved that the optimum results are obtained if the number of undulations falls within these ranges.
[0026] In an embodiment of the invention, the part of the auger extending along at least a part of the bottom of the hopper is placed in an outlet channel, which outlet channel is constituted by a trench extending along the bottom of the hopper and ending at the outlet opening, wherein the cross-sectional outline of the trench is formed by a number of straight lines, the angle between two neighbouring lines of which is obtuse.
[0027] Placing the auger in a trench having an outline as described above results in a more gentle transportation of the solid ingredients through the outlet channel without being rotated with the auger. This seems to be due to the fact that such angular shapes of the outlet channel help to “arrange” the solid ingredients in a proper way so that they are more easily being conveyed through the outlet channel.
[0028] In an embodiment of the invention, the outlet channel is asymmetric and comprises a rejector profile on the inlet side of the auger and extending parallel to the auger.
[0029] A rejector profile along the inlet side of the auger is useful for preventing solid ingredients from the hopper from being squeezed and damaged when entering the auger.
[0030] In an embodiment of the invention, the position of the auger in the outlet channel is displaced towards the inlet side of the auger with respect to the centre line of the outlet channel.
[0031] An asymmetric position of the auger results in additional space on one side of the auger, which has proven to result in a more gentle transportation of the solid ingredients through the outlet channel.
[0032] In an embodiment of the invention, the outlet pipe at its outlet end is cut off vertically at an angle with respect to the longitudinal direction of the outlet pipe, which angle is in the range from 20° to 80°, preferably in the range from 40° to 75°, most preferably in the range from 50° to 70°.
[0033] Letting the outlet pipe be cut off vertically at its outlet end at an angle with respect to the longitudinal direction of the pipe within these ranges has proved to further increase the evenness of the dosing of solid ingredients falling off the outlet end of the outlet pipe, especially when using an undulated outlet pipe as described above. This is due to the fact that the solid ingredients fall off the outlet pipe from two or more of the undulations placed at the underside of the outlet pipe, leading to less pulsation in the dosing of solid ingredients from the outlet pipe.
[0034] In an embodiment of the invention, the outlet pipe enclosing the auger is made from steel.
[0035] Making the outlet pipe from steel is advantageous that steel is an easily processable material, which is also approved for use with foodstuff.
[0036] In an embodiment of the invention, the apparatus is an apparatus for the production of ice cream mass with solid ingredients.
[0037] An auger conveyor and an apparatus as described above are very suitable for delivering solid ingredients to a lamella pump or the like for being mixed into a frozen ice cream mass.
FIGURES
[0038] A few exemplary embodiments of the invention will be described in the following with reference to the figures, of which
[0039] FIG. 1 is a schematic overview of an apparatus according to an embodiment of the invention,
[0040] FIG. 2 a is a perspective view of an auger conveyor according to an embodiment of the invention as seen from the outlet end of the outlet pipe,
[0041] FIG. 2 b is a schematic top view of the same auger conveyor,
[0042] FIG. 3 a is a perspective view an auger conveyor according to another embodiment of the invention as seen from the outlet end of the outlet pipe,
[0043] FIG. 3 b is a schematic top view of the same auger conveyor,
[0044] FIG. 4 a illustrates schematically the cross-section of an outlet pipe according to an embodiment of the invention,
[0045] FIG. 4 b illustrates schematically the cross-section of an outlet pipe according to another embodiment of the invention,
[0046] FIG. 5 a is a cross-sectional view illustrating schematically the outline of an outlet channel of an apparatus according to an embodiment of the invention,
[0047] FIG. 5 b is a cross-sectional view illustrating schematically the outline of an outlet channel of an apparatus according to another embodiment of the invention,
[0048] FIG. 6 a is a schematic cross-sectional view of a hopper and an outlet pipe of an apparatus according to an embodiment of the invention,
[0049] FIG. 6 b is a schematic top view of the same hopper and outlet pipe,
[0050] FIG. 7 is a perspective view of a hopper of an apparatus according to an embodiment of the invention,
[0051] FIG. 8 is a perspective view of an auger of an apparatus according to an embodiment of the invention, and
[0052] FIG. 9 is a side view of an apparatus according to an embodiment of the invention comprising the hopper shown in FIG. 7 and the auger shown in FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
[0053] FIG. 1 illustrates schematically an apparatus 1 according to an embodiment of the invention. The illustrated apparatus is an apparatus 1 for mixing solid ingredients (not shown), such as for instance fruit pieces, chocolate pieces or flakes, nuts, cookies or lumps of frozen jam, into a flow of at least partly frozen ice cream mass (not shown).
[0054] The mixing process is performed by a lamella pump 3 to which the frozen ice cream mass arrives through an inlet conduit 2 . The solid ingredients enters the lamella pump 3 through a top funnel 10 , and the frozen ice cream mass containing the solid ingredients leaves the lamella pump 3 and the apparatus 1 through an outlet conduit 4 .
[0055] Before being mixed into the frozen ice cream mass, the solid ingredients are stored in a hopper 5 , which at its bottom is provided with an outlet channel 11 . An auger conveyor 6 conveys the solid ingredients from the outlet channel 11 of the hopper 5 to the top funnel 10 of the lamella pump 3 by means of an auger 7 extending partly through the outlet channel 11 , partly through an outlet pipe 8 , which at its inlet end is mounted to the hopper 5 and at its outlet end terminates in the top funnel 10 of the lamella pump 3 .
[0056] The geometry of the hopper 5 , especially with regard to the outlet channel 11 thereof, the auger 7 and the outlet pipe 8 are all optimized in order to handle the solid ingredients in a gentle way without pressing them together or damaging them. These geometries also influence the evenness of the dosing of solid ingredients to the top funnel 10 of the lamella pump 3 and, thus, the evenness of the distribution of solid ingredients in the frozen ice cream mass leaving the apparatus through the outlet conduit 4 .
[0057] As for the design of the auger 6 , it is well-known to use auger conveyors 6 having augers 7 with increasing pitch and, if the auger 7 is of the type having a central core, with decreasing core diameter along the direction of conveyance. In the outlet pipe 8 , the increasing volume available for conveyance of the solid ingredients obtained thereby reduces the amount of clogging and lumping of the ingredients, which in turn results in a more even dosing of the ingredients at the end of the auger conveyor 6 .
[0058] The apparatus 1 shown in FIG. 1 deviates from previously known systems in that the inner side of the outlet pipe 8 is not cylindrical in shape but has a circular cross-sectional outline, which is superposed by a plurality of undulations as indicated in the figure. Furthermore, the outlet pipe 8 is cut off vertically at its outlet end, i.e. in the top funnel 10 of the lamella pump 3 , at an angle with respect to the longitudinal direction of the outlet pipe 8 , which is less than 90°, and the cross-sectional outline of the outlet channel 11 at the bottom of the hopper 5 also differs from being circular, which cannot be seen in FIG. 1 , however.
[0059] The dosing of solid ingredients may be controlled by weighing the hopper 5 several times per second by means of a number of weighing cells (not shown) and regulating the speed of the auger conveyor 6 in response to the results of these weighings.
[0060] FIG. 2 a is a perspective view of an auger conveyor 6 according to an embodiment of the invention as seen from the outlet end of the outlet pipe 8 . The illustrated auger 7 is of a helical type without any central core, and the generally seen cylindrical outlet pipe 8 is provided with eight undulations, each of which extends along the outlet pipe 8 running parallel to the longitudinal direction thereof. This modified shape of the outlet pipe 8 has shown to result in the solid ingredients being pushed more gently towards the outlet end of the outlet pipe 8 and in the breaking up of lumps of solid ingredients rather than formation of lumps due to solid ingredients being pressed together.
[0061] The optimum number, shape and size of these undulations may vary depending on the size and type of solid ingredients to be conveyed by the auger conveyor 6 , but numerous tests have shown that, in general, the best results are obtained using about eight undulations equally spaced around the outlet pipe 8 .
[0062] Although the outlet pipe 8 is made from steel in some preferred embodiments, it can as well be made from other materials. For instance, it may be milled out from a suitable plastic material.
[0063] In FIG. 2 b , which is a schematic top view of the same auger conveyor 6 as shown in FIG. 2 a , it is clearly illustrated how the outlet pipe 8 is cut off at its outlet end with a vertical cut, which is inclined in relation to the longitudinal direction of the outlet pipe 8 . This means that the solid ingredients, which are pushed out through the outlet end of the outlet pipe 8 by the auger 7 , will fall off the outlet pipe 8 from two or more of the undulations placed at the underside of the outlet pipe 8 , leading to less pulsation in the dosing of solid ingredients from the outlet pipe 8 .
[0064] FIGS. 3 a and 3 b similarly illustrate another embodiment of an auger conveyor 6 according to the invention, in which the auger 7 is of the type having a central core from which a helical screw flight extends, and the undulations in the outlet pipe 8 is of a more sinusoidal character than the ones shown in FIGS. 2 a and 2 b.
[0065] FIGS. 4 a and 4 b illustrate schematically the cross-sections of two other embodiments of an outlet pipe 8 . In FIG. 4 a , the outlet pipe 8 is formed with sharp-edged undulations, whereas in FIG. 4 b , the undulations have been formed by arranging a plurality of undulation profiles 9 on the inner side of a larger, cylindrical pipe, for instance by welding.
[0066] It should be noted that although the undulations shown in FIGS. 2 a , 2 b and 3 b all extend parallel to the longitudinal direction of the outlet pipe 8 , the undulations in other embodiments of the invention may extend in directions that are not parallel with the longitudinal direction of the outlet pipe 8 so that they tend more or less to wind around the outlet pipe 8 .
[0067] It should also be noted that although the undulations shown in FIGS. 2 a - 4 b all are equally spaced around the outlet pipe 8 , this may not necessarily be the case in other embodiments of the invention. In some embodiments, for instance, the undulations may be arranged in the lower half of the outlet pipe 8 only.
[0068] FIG. 5 a is a cross-sectional view of an outlet channel 11 of an apparatus 1 according to the invention illustrating how the outline of the outlet channel 11 is constituted by two vertical side walls, a horizontal bottom and two walls, each inclined at an angle of 45° from vertical, connecting the bottom and the two side walls, respectively.
[0069] In other embodiments, the cross-section of the outlet channel 11 may comprise more than five straight lines being connected at angles more obtuse than the 135° shown in FIG. 5 a.
[0070] More generally, a more gentle transportation of the solid ingredients being conveyed by the auger conveyor 6 can be obtained by creating a number of longitudinal areas with additional space around the auger 7 , for instance by constructing the outlet channel 11 from a number of elongated plane surfaces, each of which is connected to its neighbouring surface(s) at an obtuse angle.
[0071] FIG. 5 b is a cross-sectional view of an outlet channel 11 of an apparatus 1 according to another embodiment of the invention. In this case, the outlet channel 11 is asymmetric being provided on the inlet side of the auger 7 with a rejector profile 12 extending parallel to the auger 7 in order to prevent solid ingredients from the hopper 5 from being squeezed and damaged when entering the auger conveyor 6 .
[0072] Furthermore, in the embodiment shown in FIG. 5 b , the auger 7 is displaced towards its inlet side, leaving additional space on the other side of the auger 7 , which results in a more gentle transportation of the solid ingredients through the outlet channel 11 .
[0073] FIG. 6 a , which is a schematic cross-sectional view of a hopper 5 and an outlet pipe 8 of an apparatus 1 according to an embodiment of the invention, shows how a part 13 of the inner surface of the hopper 5 above the outlet opening is inclined towards the direction of conveyance of the auger conveyor 6 , i.e. towards the outlet pipe 8 .
[0074] This substantially reduces the risk of solid ingredients being stuck and/or damaged at the upper edge of the outlet opening.
[0075] FIG. 6 b is a schematic top view of the same hopper 5 and outlet pipe 8 as seen in FIG. 6 a.
[0076] FIG. 7 is a perspective view of a hopper 5 of an apparatus 1 according to an embodiment of the invention as seen from the outlet side. The figure illustrates one way of forming the inclined part 13 of the hopper wall above the outlet opening 11 of the hopper 5 .
[0077] FIG. 8 is a perspective view of an auger 7 of an apparatus 1 according to an embodiment of the invention. The figure clearly illustrates how the pitch of the auger 7 increases and the diameter of the central core 14 decreases along the direction of conveyance, i.e. from the right to the left in the figure. Especially at one point 15 corresponding to a position within the outlet channel 11 of the hopper 5 , there is a local and more significant decrease in the diameter of the central core 14 of the auger 7 as described above.
[0078] FIG. 9 is a side view of an apparatus 1 comprising the hopper 5 of FIG. 7 and the auger 7 of FIG. 8 . In this figure, it is more clearly seen how a part 13 of the hopper wall over the outlet channel 11 is inclined in the direction of conveyance, and how the most significant decrease of the diameter of the central core 14 of the auger 7 takes place at a point 15 within the outlet channel 11 of the hopper 5 .
LIST OF REFERENCE NUMBERS
[0079] 1 . Apparatus for producing frozen ice cream mass with solid ingredients
[0080] 2 . Inlet conduit for ice cream mass
[0081] 3 . Lamella pump
[0082] 4 . Outlet conduit for ice cream mass
[0083] 5 . Hopper
[0084] 6 . Auger conveyor
[0085] 7 . Auger
[0086] 8 . Outlet pipe
[0087] 9 . Undulation profile
[0088] 10 . Top funnel of lamella pump
[0089] 11 . Outlet channel of hopper
[0090] 12 . Rejector profile
[0091] 13 . Inclined part of hopper wall above outlet opening
[0092] 14 . Central core of auger
[0093] 15 . Point of most significant decline of the diameter of the core | An apparatus is disclosed comprising a hopper and an auger conveyor for conveying solid items, wherein the auger conveyor comprises an auger and an outlet pipe enclosing the auger along at least a part of the length of the auger, the outlet pipe having an inlet end and an outlet end, wherein the outlet pipe is mounted at its inlet end to the hopper for receiving solid items from the hopper through an outlet opening near the bottom of the hopper, and the auger extends partly along at least a part of the bottom of the hopper, partly inside the outlet pipe along substantially the full length thereof, and wherein at least a part of the inner surface of the hopper above the outlet opening is inclined towards the direction of conveyance of the auger conveyor. | 1 |
FIELD OF THE INVENTION
The present invention relates to a method and a core for fabricating a concrete slab by continuous slip casting, wherein an opening or a recess for optional later provision for an opening is made In the bottom surface of the slab during casting.
BACKGROUND OF THE INVENTION
In extruder-type continuous casting, concrete is extruded through the mold or nozzles of a moving casting machine by means of auger feeders and the ready-cast product remains setting on a stationary casting bed. The casting machine is propelled, e.g. by the reaction forces of the auger feeders. Other possible slip casting techniques are, e.g., the so-called slip-former technique. If so desired, hollow-core cavities can be made in the product during casting by means of shaping mandrels. The hollow-core cavities may be used, e.g., as installation ducts for piping and cables.
To accomplish such installations, an opening leading into the cavity has to be made in the surface of the hollow-core slab. The opening is usually made at the plant onto the slab resting on the casting bed by removing concrete at the cavity while the cast concrete still is fresh. If an opening is needed only in the bottom surface of the slab, it is necessary to make first an opening in the top surface of the slab resting on the casting bed only after which an opening in the bottom surface can be made. The opening made in the top surface of the slab is thus unnecessary and remains to be filled later, for instance at the construction site. Openings are also necessary in solid-core slabs, e.g. floor planks, e.g. for leading-through of sewer, air-conditioning and water pipes and electrical wiring. This kind of openings are also made at the plant by digging an opening from the top surface of the slab to the bottom surface of the slab.
Openings leading also into the hollow-core cavities are needed at the bottom surface of a hollow-core slab, e.g., as an outlet for water possibly accumulating in the cavities. These kinds of openings, e.g., relatively small water drainage openings, are normally made in the slabs at the plant the same way as described above and/or, e.g., at the construction site by drilling the finished product.
In slip casting, e.g. in the extruder or slip former techniques, the moving casting machine, instead of the casting bed, comprises also the sides that define the sides of the product. As soon as the continuously moving casting machine has traveled forward and the ready-cast product is left resting on the casting bed, the product must be in stable form and be self-supporting. This sets requirements for the concrete mix used, as known in the art. The fed concrete mix has to be dry enough so that after compaction during casting, also the hollow-core-cavities will retain their shape.
Earlier it has not been possible to incorporate separate cores on the casting bed in order to provide openings or recesses constituting provisions for openings in the bottom surface of the slab during slip casting using relatively dry concrete mix,
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a novel manufacturing method by means of which an opening, or a recess for optional later provision for an opening that can be broken through later if needed, can be obtained in the bottom surface of a concrete slab during the slip casting process. In the method according to the invention, a hole is made to the bottom surface of the slab to be cast, in a hollow-core slab substantially coinciding with a hollow-core cavity of the slab, by means of a core placed on the casting bed. The hole leads from the bottom surface of the solid-core slab to the top surface thereof, or into a cavity so as to form an opening, or, in the case of a recess for optional later provision for an opening, a thin concrete film separates the hole from top surface of a solid core slab or from the cavity of a hollow-core slab, in the cured product.
More specifically, the method according to the invention is characterized in that a core is placed on the surface of the casting bed, substantially coinciding with a cavity to be formed into the hollow-core slab, to additionally define the cross section of the concrete product to provide an opening or a recess for optional later provision for an opening in the bottom surface of the slab.
The invention also relates to a core for providing an opening in a concrete product in a slip casting process. More specifically, the core according to the invention is characterized in that the structure and/or material of the core is such that the core is capable of yielding at least partially in its vertical direction. An embodiment of the core according to the invention is characterized in that the core comprises an outer part, which advantageously is adapted to become detached from the inner core part when the cast concrete slab is elevated from the casting bed, and an inner part that advantageously is adapted to remain attached to the casting bed when the concrete slab is lifted off the casting bed.
The method according to the invention is based on placing on the casting bed a core, which enables an opening or recess for optional later provision for an opening in the slab to be cast. In case of a hollow-core slab, the core is located substantially at the site of a cavity of the hollow core. As the casting process proceeds, the casting machine casts concrete over the core, whereby a hole with the shape and thickness of the core is formed at the location of the core into the bottom surface of the slab. The thickness of the core may be adapted such that the surface(s) delimiting the top surface of the slab being cast or the hollow-core-cavity forming parts pass above the core so as to leave a concrete film of suitable thickness between the core and the surface(s) delimiting the slab top surface or, between the core and the hollow-core-cavity-forming mandrel. By thickness of the core is meant the vertical dimension of the core (i.e. height). This is how a recess for optional later provision for an opening is obtained. The said concrete film is thin enough for being broken through in the finished, cured product.
When the method according to the invention is employed at the manufacturing plant to make a through opening, i.e. a connection from the bottom surface of the slab to the cavity without a concrete film separating the hole from the cavity, a suitable core is used, preferably a core according to the present invention, whose material and/or structure yields when the casting machine passes over it and which core after the passage of the casting machine recovers its original dimensions in the vertical direction either partially or entirely, thus punching an opening into the fresh concrete film formed. This kind of said core may be e.g. a core which comprises several parts, or a part of the core, which is pressed downwards under pressure imposed thereon.
Formation of openings or recesses for optional later provisions for openings with a method according to the present invention sets requirements for a concrete mix used. The fed concrete mix has to be dry enough that the product, possibly containing also thin concrete films and left setting on the casting bed, will retain its shape.
Hence, a ready-cast solid-core slab may be provided with recesses for optional later provisions for openings at desired locations and a ready-cast hollow-core slab can have on one surface (bottom surface) one or more openings and/or recesses for optional later provisions for openings produced according to method of the invention and at desired places on the opposite surface (top surface) also openings made at the casting plant. Thus, at the construction site an opening leading from the bottom surface of the slab to the top surface of the slab or into a hollow-core cavity thereof can easily be made by breaking the thin concrete film, e.g. with a hammer, at a suitable location either entirely or partially. Especially e.g., for openings needed for water drainage, the bottom surface of the slab may be provided with small openings, whereby drilling of the slab is avoided. Water drainage holes are needed particularly in hollow-core slabs. In the present text, the term bottom surface of the slab refers to the surface of the slab facing the casting bed, while the term top surface of the slab refers to the opposite surface. Depending on the application and/or slab type, the slab may at its final erection site be installed in a position desired in which case the mentioned bottom surface of the slab need not be oriented downwards.
Among others, the invention offers the following remarkable benefits:
There is no need at the plant to break first the top surface of a hollow-core slab in order to make an opening to the bottom surface of the slab. As a result, cost savings are achieved both at the manufacturing plant and at the construction site due to the elimination of such a procedure and due to the elimination of the need for filling the unnecessary openings, respectively. There is no need at the plant to dig unnecessary openings into solid-core slabs possibly needed in the leading-through of piping and wiring. As well, the need for filling such unnecessary openings is avoided. The number, location and shape of openings and/or recesses for optional later provisions for openings can be adjusted easily because of easy attachment of the core on the casting bed and easy detachment of the same therefrom. In a fault situation during the casting process the core is easy to relocate By providing a recess for optional later provision for an opening larger than the dimensions of the opening needed, it is easy to rectify dimensional errors detected at the construction site because the recess for optional later provision for an opening, which is larger than required, does not restrict the opening to be broken exactly at the precise location decided in advance. Water drainage holes at the bottom surface of the slab need not be made by drilling.
BRIEF DESCRIPTION OF THE DRAWINGS
Next, the invention will be explained in greater detail by making reference to the attached drawings, wherein
FIG. 1 a shows a cross-sectional view of a hollow-core slab illustrating positioning of cores according to the invention;
FIG. 1 b shows a cross-sectional view of a solid-core slab illustrating the positioning of cores according to the invention;
FIG. 2 shows a longitudinal section view of a hollow-core slab manufactured according to the invention;
FIG. 3 shows some preferred embodiments of the cores used in the method according to the invention as located on a casting bed; and
FIGS. 4 a , 4 b and 4 c show sectional views of some preferred core embodiments according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 a illustrates how the hollow-core slabs may be fabricated by slip casting with a method according to the invention, for instance, as follows: Prior to the casting operation, on a metallic casting bed, i.e. a mold 1 , steel-wire pre-stressing strands 2 are pre-stressed, serving later as reinforcement in a pre-stressed element, and cores 3 are attached at desired locations in the mold coinciding with the hollow-core cavities in the casting direction. Concrete mix is poured into the feeder hopper of the slip casting machine, wherefrom the concrete falls onto the auger feeders. The rotating auger feeders force the concrete mix into a pressurized space delimited by the core-shaping mandrels and the walls delimiting the molding space, whereby the concrete mix is compacted and shaped so as to provide the final shape of the end product. The ready-cast end product 5 remains resting on the stationary casting bed for curing, while the casting machine continues to travel propelled by, e.g., the reaction forces generated by the auger feeders. The concrete mix may also be introduced onto the casting bed e.g. by pouring or pumping along troughs and fabricate a solid-core slab or a slab comprising hollow-core cavities using the slip-former casting technique well known in the art. In FIG. 1 b is shown location of a core on a casting bed in the manufacture of a solid-core slab.
Also the core delimits the casting space, whereby during casting the travel of the casting machine over the core produces at the bottom surface of the slab, a hole whose shape and size correspond to those of the core. The core thickness may be adapted such that the surface(s) of the casting machine delimiting the top surface of the solid core slab or the core-cavity shaping mandrels travel over the core so that a relatively thin concrete film 4 is left on the top surface of the core. The thickness of the concrete film is preferably 3 to 10 mm and more preferably 3 to 5 mm. A concrete film which is too thin can cause problems during casting, e.g., a part of the casting machine may interfere with the core. When a recess for optional later provision for an opening is to be made by the method according to the invention, the thickness of the film is at most such that it can be broken through in a ready-cast and cured product. Hence, it is easy to make into a finished product an opening from the bottom surface of the slab to the top surface of a solid-core slab or, an opening into a cavity of a hollow-core slab, by way of breaking, e.g. with a hammer, the thin concrete film either entirely or partially. When an opening is made with a method according to the invention, the thickness of the concrete film is maximally such that the tension build up in the core is sufficient to puncture an opening into the concrete film.
When the method according to the invention is employed at a plant for obtaining a hollow-core slab with an opening, i.e. a connection from the slab bottom surface to a cavity without a concrete film, casting is performed principally in the same way as described above, but using a suitable core which punctures the formed concrete film after casting. Such a core may be, e.g., an assembly of parts with different elastic properties or, a core wherein, e.g., part of the core yields downwards (under imposed pressure) when the casting machine travels over the said core, and which core after the passage of the casting machine thereover recovers partially or entirely its original dimensions in the vertical direction thus puncturing an opening into the formed fresh concrete film.
In FIG. 2 are shown in the bottom surface of a hollow-core slab some possible locations of openings 6 , 6 ′ and/or recesses for optional later provisions for openings 7 , 7 ′ to be obtained according to the invention. The cores may be placed by one or several hollow-core cavities. In the casting direction, that is, in the longitudinal direction of the hollow-core cavity, cores may be located at different locations and in different numbers compared to adjacent cavities. Hence, the location of openings and recesses for optional later provisions for openings on the slab surface and, hence location and number of cores on the casting bed vary according to the intended use of the slabs, openings and recesses for optional later provisions for openings. In the selection of the number and location of the cores, attention must also be paid to remain the load-bearing capability of the slab sufficient. For instance, in a hollow-core slab, the length of which is e.g. 6 to 10 m long, e.g. one to two openings 6 , 7 , can be needed e.g., for cable and/or piping installations. If the number of such openings is two, for instance, they are advantageously located e.g. at both ends of the slab. Small openings 6 ′, 7 ′, i.e. water drainage holes, are generally provided for each cavity, advantageously at both ends of a hollow-core cavity, and furthermore, a suitable number advantageously close to larger openings intended for e.g. installation of electrical cables and piping. In a solid-core slab, a suitable number of recesses for optional later provisions for openings per slab may be made at suitable locations, however, paying attention to sufficient load-bearing capability of the slab.
A finished hollow-core slab may contain one or several openings and/or recesses for optional later provisions for openings on one surface (bottom surface) using the method according to the invention, and the opposite surface (top surface) may also contain at desired locations openings made at the plant by digging out fresh concrete mix. Possible openings in the slab top surface may be provided at locations different from the openings and/or recesses for optional later provisions for openings made in the bottom surface of the slab and the sizes of the top-surface openings may vary and their number may differ from the number of openings and/or recesses for optional later provisions for openings made in the slab bottom surface. Recesses for provisions for openings may be provided at desired locations in a ready-made solid-core slab.
In FIG. 3 are shown some preferred embodiments of the cores 3 used in the method according to the invention attached to a casting bed 1 . The shape of the core facing the casting mold may be, e.g., circular, ellipsoidal or polygonal and often symmetrical. The thickness of the core may vary so that the gap between the surfaces delimiting the top surface of the solid-core slab or the lower edge of the core-cavity-forming mandrel and the top surface of the core is preferably about 3-10 mm, more preferably 3-5 mm. Depending on end-use, the distance of the lower edge of the core-shaping mandrel from the casting bed varies normally, e.g. advantageously between about 25 and 60 mm, and the thickness of a solid-core floor plank may, depending on its application, vary advantageously between about 50 and 150 mm. The dimensions of the core in the plane of the casting bed, such as core diameter, length and width, may vary according to the needs in the end-use of the slab and/or opening. For instance, openings needed for electrical cabling are often round having a diameter of about 70 to 95 mm, and air-conditioning ducts require an opening having a diameter from 100 to 160 mm. Openings intended for water drainage from a hollow-core cavity generally have a diameter of about 10 to 15 mm. The openings needed may also be longitudinal slits with a length of 2 m, for instance.
The cores may incorporate one or more magnets 8 for attaching the core on a metallic casting bed. The cores may also be attached on the mold by any other suitable way, e.g. with screws, or advantageously by glueing or by glueing with a hot-melt glue. Attachment with a magnet is particularly advantageous allowing rapid attachment of cores at suitable points of the casting bed as specified for the product. Further, detachment of cores equipped with magnets is easy after casting, and without leaving attachment marks on the casting bed that might cause problems during the next casting operation. When the cured cast slabs are detached from the casting bed, the cores or the inner parts of the cores remain on the surface of the casting bed, wherefrom they are removed, e.g., in order to change their position.
In glueing or holt-melt glueing, it is advantageous to use glue, whose strength diminishes as a function of time after curing. It is particularly advantageous to use a glue having, after setting, a sufficient strength to keep the core at its place during casting, but which glue begins to lose strength after casting. Hence, when the strength of the glue has decreased after sufficient time from the start of casting, the core can be easily detached from the casting bed, and possibly placed in a new location at the casting bed.
The cores can be located on the casting bed either manually or by mechanical means.
The core can be made of any material suitable for the application. Hence, the core can be made of, e.g., expanded polystyrene, be ceramic, be advantageously made of rubber, wood, metal or plastic, or a combination of these when an opening or recess for optional later provision for an opening is to be obtained by means of the method according to the invention.
If the ratio of the thickness of the core to its surface area facing the casting bed is relatively large, as is the case when, e.g., a recess for a provision for an opening (or an opening) is to be obtained e.g. for a water drainage hole, a core attached in place with a magnet may detach, which is not wanted, from the casting bed when the dry, finished hollow-core slab is removed from the casting bed. Similarly, a core attached in place using glue with a time-delay strength diminishing property, may become detached from the casting bed with the concrete slab. However, a narrow core may be difficult to remove from the slab. Hence, particularly when such a narrow core is used, it is advantageous to use for core, facing the concrete, a material, whose adhesion to the concrete is as low as possible.
In FIGS. 4 a , 4 b and 4 c are shown some preferred embodiments of cores according to the invention. In order to overcome the above-described problem, i.e. detachment of a narrow core from the concrete, one possibility is to use, e.g., a core ( FIG. 4 c ) comprising an outer and an inner part. When such a combination core is used, the inner part of the core, advantageously the said core equipped with a magnet, can remain attached to the casting bed while the outer core is removed with the concrete slab. The material of the outer part of the core, or its surface material can be different from the material of the inner part of the core. When using the mentioned outer core part, the adhesion between the outer core part and concrete being low, the core or outer part of the core attached to it, is easy to detach afterwards from the concrete. Such outer parts of the core may be advantageously reused several times. Preferably, the core surface facing the concrete is also as smooth as possible to facilitate the detachment of the core from the concrete. The outer part of the core is advantageously made of plastic, for instance. The mentioned narrow type core may also be of one part, in which case the core surface facing concrete is advantageously coated with a low-adhesion material, e.g. with PTFE. Also the surface of the outer part of a multipart core can advantageously be coated with a low-adhesion material, e.g. with PTFE. The material of the core or part of the core facing concrete must possess sufficient stiffness to resist pressure imposed on it during casting. The shape of outer part of the core (i.e., the part facing the concrete) may, e.g., substantially follow the form of the inner core.
When producing openings using the method according to the invention, a core can be used, advantageously of the kind in accordance with the invention, whose structure and/or material is such that the core can yield at least partially at least in its vertical dimension. Some embodiments of this kind of core are such as e.g. those illustrated in FIGS. 4 a and 4 b , made of a material that may yield under the pressure generated during casting. The cores of FIGS. 4 a and 4 b comprise a magnet for attaching the core onto a casting bed. However, the magnet is not necessarily needed in the cores and they may as well be attached onto the casting bed by any other suitable way, for instance, by such ways of attachment, which are disclosed earlier in the text for attachment of cores onto a casting bed in conjunction for obtaining recesses for optional later provisions for openings in slip casting.
One further embodiment of a core according to the invention may be such core as is illustrated in FIG. 4 c , comprising an outer part and an inner part, which core yields either entirely or partially in the vertical direction under pressure generated during the event of casting, so that the core or at least the outer part thereof during casting “evades” the casting machine by way of yielding downwards in vertical direction in such fashion that a thin concrete film remains between the lower edge of the core-shaping mandrel and the top of the core and, after the passage of the casting machine, the core or, alternatively, its outer part recovers its original dimensions in the vertical direction either partially or entirely thus punching an opening into the said concrete film.
The core or the outer and/or inner part of the core in accordance with the invention may be made of any material suitable to the purpose. The core can be made of, e.g., expanded polystyrene, be ceramic, or be advantageously made of rubber, wood, metal or plastic, or of any combination of these. A core that comprises several parts may be fabricated such that the parts of the core are of the same material or of different materials, and part of the core can be fabricated using more than one material, advantageously selected from the materials mentioned above.
To accomplish vertical compressibility of the core according to the invention, the lower portion of the outermost core may be made, e.g., of a material different from that used in the other portion of the outermost core, e.g. advantageously being more elastic plastic or rubber. This kind of lower edge which is made of the same or different material and is suitably elastic, advantageously also functions as a seal so that concrete mix is substantially prevented from entering between the outer part of the core and the inner part of the core during casting. The outer part of the core can be attached in a suitable way to the inner core part. The fixing of the outer part of the core with regard to the casting machine principal plane during casting may be enhanced e.g. by selecting the material of the lower edge of the outermost part of the core so, that the friction between said material and the casting bed is sufficient to fix the outer part of the core during casting. | A method is provided for fabricating a concrete slab in a substantially horizontal slip casting process method, concrete mix is fed into a mold through a delimited cross section moving progressively in the casting process so as to form a concrete product of a desired shape. Onto the surface of the casting bed ( 1 ) is placed a core ( 3, 9, 10, 11 ) capable of delimiting the cross section of the concrete product ( 5, 5 ′) so as to provide an opening or a provision for an opening in the bottom surface of the slab. A core is provided for obtaining an opening or a provision for an opening. The structure and/or material of the core is/are such that the core is capable of yielding in vertical direction. A core may also be a multipart core, the outer part of which becomes detached from the inner part of the core in conjunction with lifting off the concrete slab from the casting bed. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/408.582, filed Nov. 3, 2010, titled PERSONAL HYGIENE DEVICE, incorporated herein by reference.
FIELD OF THE INVENTION
[0002] Some embodiments of the present invention pertain to apparatus for safe storage and transportation of personal hygiene devices, and in particular to such devices adapted and configured to hang from a door.
SUMMARY OF THE INVENTION
[0003] One aspect of the present invention pertain to an apparatus for storing objects. Some embodiments include a container having an interior and first and second ends and an opening providing access to the interior. Other embodiments include a support member rotatably coupled to the container, the member having two ends, one of the ends being generally in the shape of a first hook. Yet other embodiments include a second hook having an opened end, the second hook being coupled to the support member proximate the other end of the support member and movable between stowed and deployed positions relative to the support member, wherein in the stowed position the opened end of said second hook can receive therein an end of the container, and in the deployed position the second hook and the first hook have the general shape of an “S”.
[0004] Another aspect of the present invention pertains to a container having an interior and first and second ends, an opening providing access to the interior, and a cap covering the opening. Other embodiments include first and second hooks each having an opened end and each hook extending from the container, the first hook being positionable to support the container, the second hook being positionable to support an object from the container; wherein the container is rotatable relative to the first and second hooks.
[0005] It will be appreciated that the various apparatus and methods described in this summary section, as well as elsewhere in this application, can be expressed as a large number of different combinations and subcombinations. All such useful, novel, and inventive combinations and subcombinations are contemplated herein, it being recognized that the explicit expression of each of these combinations is unnecessary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Some of the figures shown herein may include dimensions. Further, some of the figures shown herein may have been created from scaled drawings or from photographs that are scalable. It is understood that such dimensions, or the relative scaling within a figure, are by way of example, and not to be construed as limiting.
[0007] FIG. 1 a is a front plan view of a personal hygiene device according to one embodiment of the present invention shown in the closed position.
[0008] FIG. 1 b is a right side elevational view of the apparatus of FIG. 1 a.
[0009] FIG. 1 c is a top plan view of the apparatus of FIG. 1 a.
[0010] FIG. 2 a is a front plan view of a personal hygiene device according to one embodiment of the present invention shown in the opened position.
[0011] FIG. 2 b is a right side elevational view of the apparatus of FIG. 2 a.
[0012] FIG. 2 c is a top plan view of the apparatus of FIG. 2 a.
[0013] FIG. 3 a is a front elevational view of a part of the assembly of FIG. 1 a.
[0014] FIG. 3 b is a right side elevational view of the apparatus of FIG. 3 a.
[0015] FIG. 3 c is a top plan view of the apparatus of FIG. 3 a.
[0016] FIG. 3 d is a front elevational view of a part of the assembly of FIG. 1 a.
[0017] FIG. 3 e is a right side elevational view of the apparatus of FIG. 3 d.
[0018] FIG. 3 f is a top plan view of the apparatus of FIG. 3 d.
[0019] FIG. 4 a is a front elevational view of a part of the assembly of FIG. 1 a.
[0020] FIG. 4 b is a right side elevational view of the apparatus of FIG. 4 a.
[0021] FIG. 4 c is a top plan view of the apparatus of FIG. 4 a.
[0022] FIG. 5 a is a front elevational view of a part of the assembly of FIG. 1 a.
[0023] FIG. 5 b is a right side elevational view of the apparatus of FIG. 5 a.
[0024] FIG. 5 c is a top plan view of the apparatus of FIG. 5 a.
[0025] FIG. 6 a is a front elevational view of a part of the assembly of FIG. 1 a.
[0026] FIG. 6 b is a right side elevational view of the apparatus of FIG. 6 a.
[0027] FIG. 6 c is a top plan view of the apparatus of FIG. 6 a.
[0028] FIG. 7 a is a top, front, right, perspective view of the apparatus of FIG. 1 a.
[0029] FIG. 7 b is a view of the apparatus of FIG. 7 a , except rotated to a partially opened position.
[0030] FIG. 7 c shows the apparatus of FIG. 7 a in the fully opened position.
[0031] FIG. 8 a is a top, front, right, perspective view of an apparatus according to another embodiment of the present invention.
[0032] FIG. 8 b is a top, rear, right, perspective view of the apparatus of FIG. 8 a.
[0033] FIG. 9 a is a perspective view of an apparatus according to one embodiment of the present invention.
[0034] FIG. 9 b is a perspective view of the apparatus of FIG. 9 a.
[0035] FIG. 10 a is a close-up of a portion of the apparatus of FIG. 8 b.
[0036] FIG. 10 b is a close-up view of the portion of FIG. 10 a from a different angle.
[0037] FIG. 11 a is a close-up of the top of FIG. 8 a.
[0038] FIG. 11 b is a portion of the assembly of FIG. 11 a.
[0039] FIG. 11 c is a view of the apparatus of FIG. 11 b as taken from the rear.
[0040] FIG. 11 d is a view of the apparatus of FIG. 11 a as taken from the rear.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. At least one embodiment of the present invention will be described and shown, and this application may show and/or describe other embodiments of the present invention. It is understood that any reference to “the invention” is a reference to an embodiment of a family of inventions, with no single embodiment including an apparatus, process, or composition that should be included in all embodiments, unless otherwise stated. Further, although there may be discussion with regards to “advantages” provided by some embodiments of the present invention, it is understood that yet other embodiments may not include those same advantages, or may include yet different advantages. Any advantages described herein are not to be construed as limiting to any of the claims.
[0042] The use of an N-series prefix for an element number (NXX.XX) refers to an element that is the same as the non-prefixed element (XX.XX), except as shown and described thereafter The usage of words indicating preference, such as “preferably,” refers to features and aspects that are present in at least one embodiment, but which are optional for some embodiments. As an example, an element 1020 . 1 would be the same as element 20 . 1 , except for those different features of element 1020 . 1 shown and described. Further, common elements and common features of related elements are drawn in the same manner in different figures, and/or use the same symbology in different figures. As such, it is not necessary to describe the features of 1020 . 1 and 20 . 1 that are the same, since these common features are apparent to a person of ordinary skill in the related field of technology. This description convention also applies to the use of prime (′), double prime (″), and triple prime (′″) suffixed element numbers. Therefore, it is not necessary to describe the features of 20 . 1 , 20 . 1 ′, 20 . 1 ″, and 20 . 1 ′″ that are the same, since these common features are apparent to persons of ordinary skill in the related field of technology.
[0043] Although various specific quantities (spatial dimensions, temperatures, pressures, times, force, resistance, current, voltage, concentrations, wavelengths, frequencies, heat transfer coefficients, dimensionless parameters, etc.) may be stated herein, such specific quantities are presented as examples only, and further, unless otherwise noted, are approximate values, and should be considered as if the word “about” prefaced each quantity. Further, with discussion pertaining to a specific composition of matter, that description is by example only, and does not limit the applicability of other species of that composition, nor does it limit the applicability of other compositions unrelated to the cited composition.
[0044] Each of the drawings shown herein are presented substantially as scaled drawings. However, the scalings indicated on some drawings (such as scale of 3:4 on FIG. 2 a ) are not accurate. Further, FIGS. 1 , 2 , 3 , 4 , and 5 are shown in a standard orthogonal format. Additionally, more numbers and arrows on some drawings, such as FIG. 2 b and FIGS. 3 , 4 , 5 , and 6 represent dimensions (in centimeters) for a particular embodiment. It will be appreciated that some drawings are shown in a wire frame format, whereas other drawings (such as FIG. 7 ) are shown with shaded external surfaces.
[0045] FIG. 1 show three orthogonal views of a portable personal hygiene device 20 according to one embodiment of the present invention. Device 20 includes a rotatable assembly 22 that is pivotally coupled to a hanging assembly 24 . In one embodiment, the external dimensions of assemblies 22 and 24 are adapted and configured to provide a compact overall envelope, as best seen in FIG. 1 c. FIG. 1 show device 20 in the closed position, which is suitable for carrying.
[0046] FIG. 2 show the device of FIG. 1 in the opened position. Device 20 ′ includes a sliding hook 40 ′ that translates along a guide 36 a of hanging assembly 24 ′. Hanging assembly 24 ′ supports rotatable assembly 22 ′ such that a relative rotational displacement of about ninety degrees can be established between static assembly 24 ′ and rotating assembly 22 ′ in an anti-clockwise direction (with reference to FIG. 2 a ). As best seen in FIG. 2 b , the extended position of hook 40 ′ is to the rear of device 20 ′. A second, static hook 32 extends forward on assembly 24 ′, in a direction opposite to that established by hook 40 ′. In some embodiments, sliding hook 40 ′ is adapted and configured to support device 20 ′ from a doorway (such as the doorway to a stall or partition of a stall in a public restroom). Static hood 32 is oriented in the upward direction in order to accommodate a coat, handbag, briefcase or other clothing of the restroom user. As best seen in FIG. 2 b , when sliding hook 40 is extended to a deployed position the hooks 40 and 32 resemble an “S” shape.
[0047] Although what's been shown and described is a hook 40 that is movable relative to spine 30 such that it slides relative to spine 30 , yet other embodiments are not so constrained. In one embodiment, hook 40 is rotatably movable relative to spine 40 . In such embodiments, hook 40 is rotatably coupled to spine 30 , and with reference to FIG. 2 b, could be rotated one hundred and eighty degrees about a centerline extending along spine 30 . In such embodiments, the opened end of the hook 40 can include a projecting shoulder, similar to the shoulder of hook 32 .
[0048] FIGS. 3 a , 3 b , and 3 c show a component of device 20 in three orthogonal views. Main spine 30 includes an elongated central member that interconnects a static hook 32 at one end, and a T-shape guide 36 a at the other end. As best seen in FIG. 3 a , guide 36 a includes a pair of laterally and oppositely extending flanges that are connected by a central neck 38 . Referring to FIG. 3 b , it can be seen that the flanges 36 a extend along a depth relative to the central joining member. The static hook 32 at the bottom of spine 30 extends forward in a manner and depth similar to that of guide 36 . Hook 32 preferably includes a vertically upward-extending nose around which a clothing loop or clothing cuff can be hung. About midway along the central joining member and intermediate of guide 36 and hook 32 is a semi-spherical indentation 34 used for joining spine 30 to rotatable assembly 22 .
[0049] FIGS. 3 d , 3 e , and 3 f are orthogonal views of a hook 40 that receives within a slot 46 the T-shape guide 36 of spine 30 . Referring to FIG. 3 d , slot 46 can be seen having an upper, horizontal slot that accepts the lateral flanges 36 a of spine 30 . A central portion of slot 46 is adapted and configured to receive neck 38 . Preferably, hook 40 includes a pair of stabilizing shoulders 48 . Shoulders 48 are received around neck 38 in the closed position. When hook 40 is slid to the open position, shoulders 48 comprise a downward projection as part of a hook structure in conjunction with the central member of spine 30 (as seen previously in FIG. 2 b ).
[0050] FIG. 4 show orthogonal views of a generally cylindrical body 50 according to one embodiment of the present invention. Body 50 includes an integrally molded and semi-spherical ball 54 that is located intermediate of the ends (as best seen in FIG. 4 b ), and which is received in the assembled device 20 by the socket 34 of spine 30 . A fastener (not shown) completes attachment of ball 54 to socket 34 .
[0051] Referring to FIGS. 4 a and 4 c , cylinder 50 defines an internal volume 53 that is adapted and configured to receive within it an item of personal hygiene, such as a roll of toilet paper 10 . Cylinder 50 further defines a slot 56 through which the item received within interior 53 can be externally accessed by the user.
[0052] FIG. 5 show three orthogonal views of a clip-on compartment 60 . Compartment 60 includes a pair of cylindrical segments 63 that are interconnected by a cylindrical storage compartment 62 . As best seen in FIG. 5 b , the clips 63 are adapted and configured (preferably by a combination of wall thickness, material stiffness, and cutout angle) to be expanded to receive within them an end of cylinder 50 . Compartment 62 defines an internal volume for storage of another item of personal hygiene, such as a toothbrush or a tampon.
[0053] FIG. 6 show orthogonal views of an end cap 70 according to one embodiment of the present invention. End cap 70 includes an axle 76 coupled to an endplate 72 . A knurled finger grip 74 extends around the periphery of endplate 72 . Further, as best seen in FIG. 6 b , endplate 72 can also include an angular segment of reduced thickness, which is useful either for applying a moment to end cap 70 , or to visibly show the angular orientation of endcap 70 . In some embodiments, axle 76 is adapted and configured to be received within the hollow support tube of a roll of toilet paper. In one embodiment, device 20 includes a pair of endcaps 70 that are received within different ends of cylinder 50 (as seen in FIGS. 1 b and 2 a ). In some embodiments, endplates 72 include latching features for coupling the endplate to the ends of outer cylinder 50 . In yet other embodiments the internal end of axle 76 is adapted and configured to interlock with the other axle inserted within the cylinder 50 . End caps 70 preferably defines an internal cavity 78 suitable for storage of personal hygiene items, such as wet wipes or toilet seat covers by way of example.
[0054] FIG. 7 show device 20 being reconfigured from the closed configuration ( FIG. 7 a ) to the open configuration ( FIG. 7 c ). Referring to FIG. 7 b , it can be seen that the periphery of the end caps 70 come closest to spine 30 in a partially opened state. The length and diameter of cylinder 50 and the distance between the upper surface of hook 32 and the lower surface of guide 36 are adapted and configured to provide clearance between rotating assembly 22 and static assembly 24 in the position depicted in FIG. 7 b.
[0055] FIG. 8 show a personal hygiene device 120 according to another embodiment of the present invention. Device 120 operates and is constructed in a manner similar to that of device 20 , except as will now be shown and described. FIG. 8 a shows the rotating assembly 122 in the closed and fully nested position within hanging assembly 124 . Portably personal hygiene device 120 includes a pair of storage compartments 162 that are coupled to clip assembly 160 . Referring to FIG. 8 b , it can be seen that a knob 158 provides a connection between spine 130 and rotatable assembly 122 .
[0056] FIG. 9 show perspective views of a cylinder 150 according to another embodiment of the present invention. Cylinder 150 includes an integral end cap 151 a. And integrally molded axle 151 b extends inwardly within volume 153 . Therefore, device 120 includes only a single, separate end cap 170 . In some embodiments, the separate end cap 170 includes an internal cavity 178 for storage of personal hygiene devices. In yet other embodiments, and as best seen in FIG. 9 b , integral end cap 150 a includes an internal cavity 178 for storage of personal hygiene items.
[0057] FIG. 9 b shows the integrally molded knob 158 that is part of cylinder 150 . Knob 158 includes a central, cylindrical portion, and two outwardly extending projections 158 a and 158 b.
[0058] FIG. 10 depict the attachment of cylinder 150 to spine 130 . Spine 130 includes a cutout slot 139 in place of the socket 34 of spine 30 . This cutout 139 includes a generally spherical central portion 139 b with a pair of elongate slots 139 a on opposite sides of the central hole. In order to assemble cylinder 150 to spine 130 , knob 158 is aligned with slot 139 , and pushed through the central wall of spine 130 until the projections 158 b extend past the back surface of the central wall. Cylinder 160 is then rotated about the axis created by placement of cylinder 158 b within central aperture 139 b. Cylinder 160 is rotated until a projection 158 a encounters a flexible projecting latch 137 a. Since latch 137 a is flexible, the operator can continue rotating cylinder 160 until the projection 158 a snaps across latch 137 a from one side to the other side.
[0059] In this position, cylinder 160 is able to rotate 90 degrees relative to spine 130 . Limits on this relative rotation are established by latch 137 a and stop 137 b. As shown in FIG. 10 a , cylinder 160 is in the closed position. As seen in FIG. 10 b , the projection 139 a is in contact with stop 137 b, and the cylinder 160 is in the opened position. In order to remove cylinder 160 from spine 130 , the cylinder is returned to the closed position, and the operator bends latch 137 a so that it does not interfere with rotation of projection 158 a back toward slot 139 .
[0060] FIG. 11 depict the coupling of sliding latch 140 to spine 130 . FIG. 11 a shows hook 140 in the closed, fully-nested position on spine 130 . FIG. 11 b shows hook 140 removed from spine 130 . A fastener 125 extends within a hole 141 .
[0061] FIG. 11 c shows spine 130 without sliding hook 140 . Spine 130 defines a female guide slot 136 b. Referring to FIG. 11 d , the fastener 125 attaches to hook 140 a pin 142 that is adapted and configured to be received within slot 136 b. Pin 142 is attached to hook 140 after placement of the hook on spine 130 , in one embodiment. As can be appreciated from FIG. 11 d , hook 140 can be slid backwards (i.e., toward the viewer out of the plane of FIG. 11 d ), and the sliding motion of hook 140 will be stopped by contact of pin 142 with an end of slot 136 b.
[0062] While the inventions have been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | Apparatus and methods for storing and carrying personal item. In one embodiment, the storage container is nested within a pair of opposing hooks in a stowed position. In a deployed position, the container can be rotated relative to each of the hooks. Further, one of the hooks can be moved to a deployed position such that the apparatus can be hung from the deployed hook, and further such that an object such as a coat or a purse can be suspended from the second hook. | 0 |
BACKGROUND OF THE INVENTION
Although rotary internal combustion engines have reached a degree of commercial acceptance, considerable interest is now being devoted to improving fuel economy and durability of such engines. The water cooling system for such an engine is particularly relevant to attaining these two goals. The housing water cooling system, in a rotary engine, functions to lower the temperature of the metal areas exposed to the highest heat input and to minimize temperature differences throughout the housing for preventing destruction. The most severe cooling problem resides in the area where combustion and expansion of the working gases takes place; this area immediately surrounds the spark plugs. The uneven heating can cause housing distortion which, in turn, can prevent proper functioning of the gas and oil sealing elements. The time during which the combustion chamber is cooled by fresh inducted air is fairly short allowing the wall temperature of the combustion chamber to be high and sensitive to changes in load. The maximum temperature of the combustion surface of the trochoid wall is much higher than that of the housing side walls; local overheating can destroy the oil film on the trochoid surface. Sudden acceleration with a cold engine, especially in winter or when auto ignition occurs during high speed driving, exposes the rotor housing and associated trochoid wall to repeated sudden and very large thermal loads. As a result, thermal fatigue or thermal shock cracks can appear about the spark plug holes. In general, cracks occur most frequently on the gas side of the trochoid wall and along the spark plug holes in the axial direction in conformity with high stress concentrations. In extreme cases, cracks can even reach the water jacket. There is a greater need for perfection in design to limit this tendency for thermal distortion which is so highly dependent on the relationship between the cooling system, housing and rotor seals.
One particular design aspect that has assumed commercial acceptance, is the use of in-line or dual spark plugs for a single rotor housing. The reason for the dual in-line spark plugs is as follows: In a rotary piston engine with a rotor rotating eccentrically along an inside surface having a trochoid curve, it is ideal for the spark plugs to be installed on the trochoid surface close to the minor axis of the curve, from the standpoint of engine output. However, since the compressed air-fuel mixture also undergoes a rotating motion along with the rotation of the rotor, the rotary engine has a characteristic flame front which advances to the leading side of the rotor and has very little propagation to the trailing side of the rotor. Therefore, the air-fuel mixture disposed in the trailing portion of the rotor combustion pocket is not completely burned. Consequently, the exhaust gas will contain a large amount of unburned gaseous components. To remedy this, another or auxiliary spark plug is installed downstream from the first spark plug and the latter is moved slightly upstream; the auxiliary spark plug is ignited after the first spark plug has been ignited, or in certain cases they may be ignited simultaneously. The necessity for the in-line arrangement is due to the physics of propagation and the desire to have the entire air-fuel mixture totally combusted. The optimum location to do this was thought to be in the center of the peripheral wall whereby the flame front would advance in the direction of movement of the air/fuel mass and proceed laterally across the shortest path toward each of the side walls to combust all of the mixture. Unfortunately, the in-line arrangement of such spark plugs creates a mechanism by which the flow of cooling fluid is considerably disrupted, vapor films collect, and the flow is prevented from carrying away the heat in such a critical area.
Spark plugs for an internal combustion engine, such as a rotary, are typically installed into the threaded ports of the spark plug bosses. Since a rotary engine has a relatively thin trochoid wall, cylindrically shaped bosses for the spark plugs must be cast and extend into the engines water jacket passageway which is adjacent to such wall. The interruption or interference of such bosses within the water jacket passageway has a benefit in that the bosses themselves are cooled to carry away heat but the total heat for the entire hot spot area is detrimentally affected; the cooling flow is extremely sensitive to hindrances preventing heat extraction. Each boss in a four-cylinder reciprocating engine will be affected by generally 1/4 of the total heat of combustion for the engine. This is not a severe problem in connection with reciprocating type internal combustion engines since the spark plug bosses are well separated in the cylinder heatt water jacket and, in fact, can be considered as one spark plug per cylinder. However, in contradistinction, the spark plug bosses in a rotary engine are cast in close proximity to the circumference of each rotor housing, do not have special coolant transfer ports for improved cooling, and are generally affected by 1/2 of the total heat of combustion for a two rotor engine (for a one rotor engine, the bosses would be effective by the total undivided heat of combustion).
As the rotary design has developed, spark plugs have been fitted into the threaded ports which open onto the most critically cooled zone of the trochoid combustion surface - a major hot spot where thermally induced structural failures are more likely to occur. If the cooling flow cannot carry away the heat in a uniform manner, the exact amount of excess heat in such hot spot will cause detrimental results. The in-line arrangement of spark plug bosses in such water passageway contributes, in a significant manner, to preventing adequate heat extraction. Particularly in the vertically upward flow of the cooling circuit, where in-line spark plugs are typically placed, the up-stream plug boss creates a flow shadow effect upon the down-stream plug boss preventing a controlled or well ordered flow regime (absence of swirling eddies which deteriorate heat transfer). Boiling at the plugs results in a vapor stream which widens the uncontrolled flow zone and aggravates the heat transfer problem.
SUMMARY OF THE INVENTION
A primary object of this invention is to provide an ignition and cooling system combination which is effective to maintain an efficient level of combustion while improving cooling characteristics to reduce the possibility of structural failure of the engine's housing.
Another object of this invention is to provide a housing structure which facilitates circumferential cooling flow in the rotor housing while permitting the intrusion of spark plug bosses therethrough, the housing being structured to minimize thermal distortion, particularly in the zone surrounding said spark plug bosses.
Still another object of this invention is to provide a housing for a rotary internal combustion engine having a peripheral cooling circuit defined so that there are separate flow paths for release of boiling vapor from a plurality of spark plug bosses interrupting such circuit.
Yet still another object of this invention is to provide a housing structure for a rotary internal combustion engine which employs circumferential cooling having a vertical flow moving past bosses therein which are an integral part of said structure, the structure being made to increase the heat transfer coefficient of said cooling circuit at the spark plug boss zone by at least 20 % over prior art capabilities.
Structural features pursuant to the above objects comprise the use of (a) plug bosses interposed in a circumferential cooling flow passageway of the rotor housing, and staggered with respect to the direction of flow, the arrangement of the plurality of spark plugs and accompanying bosses are offset but symmetrically oppositely oriented about a centerplane of said flow and skewed with respect thereto so that the staggered arrangement promotes relatively close in-line arrangement of the spark plug terminals, (b) the incorporation of a predetermined and limited offset from a line extending between the spark plug terminals so as not to detrimentally affect propagation of the combustion flame while yet allowing for said staggered boss configuration, and (c) the use of flow diverters or flow controllers between the spark plug bosses to insure a controlled flow regime between the bosses and for strengthening the housing structure.
SUMMARY OF THE DRAWINGS
FIGS. 1 and 2 represent schematic illustrations of spark plug boss arrangements for the inventive mode and the prior art mode respectively;
FIG. 3 is a sectional elevational view of one rotor housing and rotor for a multi-rotor rotary internal combustion engine embodying the principles of this invention;
FIG. 4 is a view taken substantially along line 4--4 of FIG. 3;
FIG. 5 is a side elevational view of the fragmentary structure of FIG. 4; and
FIG. 6 is an end elevational view taken along line 6--6 of the fragmentary structure of FIG. 4.
DETAILED DESCRIPTION
Spark plugs for any type of internal combustion engine are typically installed into threaded openings within spark plug bosses. The cylindrically shaped bosses are cast into the engine water jacket passageway to prevent cracking of the support structure due to thermal distortion. Coolant flow velocities are directed over these critically cooled surfaces of the bosses to lower the metal temperatures and, ideally, to prevent excessive temperature variation across the walls defining said passageway (i.e., hot spots which induce thermal distortion and attendant failure of the housing structure).
Turning to FIG. 2, there is schematically illustrated in plan view, an arrangement characterized as "in-line" for bosses 8 and 9 with respect to a centerplane 54 extending through a water jacket passage of a typical prior art rotor housing. Cooling flow is aggravated during boiling heat transfer at high engine power settings; vapor released from the upstream boss surfaces induce further variations in the coolant velocity distribution across the downstream boss laying in the flow shadow of the upstream boss for the in-line arrangement. In FIG. 1 there is, schematically shown, bosses which are staggered with respect to the centerplane 54 of flow of the coolant in the water jacket passage for a rotary engine employing the principles of this invention. The construction of FIG. 2 provides superior coolant performance about the circumference of each spark plug boss when compared to closely spaced "in-line" bosses, the latter preventing high speed coolant flow between the bosses. The distribution of coolant velocities around the staggered spark plug boss surface is improved since flow around each boss is less dependent on the presence of the other boss in the water jacket passageway. The vapor released from the upstream boss is carried away from the coolant stream impinging on the downstream boss. This reduces locally high thermal conditions by improving the distribution of coolant velocities around the boss surface and hence the engine water jacket by providing separate paths for vapor release during boiling heat transfer.
In some particularity, a preferred embodiment is shown in FIGS. 3-6. The rotary engine of FIG. 3, comprises a housing A, a rotor B, an induction system or means C, an ignition system D, means E which is effective to define a cooling passageway, and boss means F useful in containing the ignition means within the water passageway.
The housing A has an internal wall 10 which is epitrochoidally shaped to delimit a chamber in cooperation with side housings disposed on opposite sides of housing A (rotor housing). The epitrochoid chamber has a minor axis 11 and a major axis 12. The rotor C is generally triangularly shaped with three outer arcuate faces 13; apex seals 14 are disposed at the apices where the faces 13 intersect. The seals cooperate in defining with the rotor and housing a plurality of variable volume combustion chambers 15, 16 and 17. The rotor is mounted for planetary movement within the trochoidally limited chamber bounded by an internal epitrochoid wall 10 and has an eccentric surface 18 which is in contact with an eccentric shaft 19.
A combustible mixture is inducted through system C; the system has a carburetor 22 effective to inject said mixture through intake passage 20 leading to the trochoid chamber. An exhaust passage 21 withdraws the exhaust gases upon completion of the combustion cycle. The ignition means D utilizes a plurality of spark plugs, here shown two in number, 25 and 26, which are arranged at stations on opposite sides of the minor axis 11. The spark plugs may be of the conventional flat-gap type and each has a threaded portion 28 received in a threaded portion of a bore in said boss means F. The spark plugs have terminal portions 27 and 29 respectively with appropriate lead-in electrical wires 30 for carrying a pulse of energy to excite sparks in a precise sequence. The terminals 27 and 29 are almost coincident with the trochoid surface 10 and therefore can be represented in our discussion by substantially a point station.
Means E, defining the cooling passage, extends from an entrance at 31 into the housing (at about a 7 o'clock position) to an exiting station 32 (at a 1 o'clock position). The housing means E comprises a wall 34 separating the trochoid chamber 10 from the cooling passage E and has a predetermined thickness which is relatively thin. The passage may have one or more rather elongated ribs 33 for guiding or structurally reinforcing the housing passage. The flow proceeds along a path which has a centerline 46 and has a substantial segment thereof which is rising vertically along the side of the rotor housing A.
The boss means F comprises two cylindrically shaped and cast bosses 41 and 40 which extend across the passageway at a location adjacent the vertically rising section of said flow. The centerline, 44 and 45 respectively, of each boss is skewed with respect to a centerplane 54 dividing the passageway longitudinally. The bosses have an arrangement such that the terminal of each spark plug will project onto a point on the trochoid wall 10 preferably offset a distance 60 (from the centerline 61 of said trochoid wall (see FIG. 1). The combined offset distances are less than the diameter of either of said bosses. The bosses are arranged so that, looking at them along the passageway, they show frontal or upstream portions 40a and 41a which are substantially non-overlapping whereby fluid flow of a high velocity may scavenge such surfaces and prevent the collection of vapor generated at such hot surfaces. Vapor generation tends to collect and develop a vapor binding film 50 along the upstream side of each boss in an "in-line" situation (see FIG. 2). Ideally, the positioning of the terminals 27 and 29 of each spark plug for this invention approach an in-line arrangement on the trochoid surface 10 (gas side of wall 34), while the bosses are arranged to effect a very definite and noticeable offset arrangement in the passage E. The bosses are packaged in the housing in such a manner that the boss centerlines 44 and 45 will each form an angle 70 with respect to the plane 54 dividing the coolant passage longitudinally and an angle 72 with respect to a plane 55 dividing the coolant passage transversely. The range for such angles is as follows: Angle 70 is preferably about 25°-65° and angle 72 is preferably about 15°-55°, but operably can be reduced to 0° for each angle. The cylindrical trunk of each boss has the terminals 27 and 29 spaced apart a longitudinal distance 51 which is typically less than 12 diameters of each boss; the distance 51 is somewhat limited by the pocket 73 design for the rotor. However, irrespective of the pocket design, if the boss diameter is relatively small so that side wall effects on the flow about the bosses can be ignored, then this invention is important for spacings between bosses up to 50 boss diameters. In applications where the boss diameter is relatively large with respect to the width of the cooling passage, side wall effects will be present and the invention will be important for longitudinal spacings between bosses of up to 12 diameters.
As a result of the staggered configuration of the spark plug bosses, high velocity flow therethrough is controlled and devoid of uncontrolled swirling eddies so that a high heat transfer coefficient can be maintained at the sensitive spark plug boss surfaces. Geometrically, the flow is split into several paths as it swings to different sides of the upstream spark plug boss 40 and thence at portion divides about the downstream boss 41. Accordingly, vapor released from either one of the boiling surfaces of the spark plug bosses enters the swinging controlled split paths.
Tests were undertaken to visually compare the flow regime of a water model passageway simulating the passage plug bosses. Two models are undertaken, one with staggered spark plug bosses and one with "in-line" spark plug bosses. Small neutral density plastic particles, entrained in the water flow stream, were used to trace the contours of the coolant flow path. In addition, electrolysis of the water was employed to produce hydrogen gas (bubbles smaller than the vapor bubbles typically encountered in the rotary engine). The hydrogen gas was found to collect in rather large crescent shaped zones 50 on the upstream side or frontal face 40a and and 41a of the in-line bosses, such as shown in FIG. 2. However, with the staggered spark plug configuration, high speed controlled flow sweeps these vapor particles clean from such upstream sides or frontal faces and it has been determined that the heat transfer coefficient between the flow and bosses is increased by as much as 44% for the model study. To relate this to an actual engine housing, the change in heat transfer rate was calculated utilizing a maximum flow velocity of about 4.1 feet per second and volume flow rate of about .033 cubic feet per second. The temperature of the coolant flow at the wall was measured to be approximately 320°F and at the coolant flow centerline at about 225°F, thereby rendering an average coolant flow temperature of about 270°F; the minimum projected area of the passageway about the zone adjacent the spark plug bosses was 1.17 square inches. Calculation of the Reynolds number for the flow determined it to be about 1.2 × 10 5 (a non-dimensional number) which indicated that the flow was in a controlled turbulent condition. The heat transfer coefficient, calculated for the "in-line" arrangement, was about 1800 Btu/Hr/Ft 2 /°F. This was in sharp contrast with the heat transfer coefficient calculated for the staggered arrangement which was about 2600 Btu/Hr/Ft 2 /°F. [The diameter of the spark plug boss as assumed to be about .85 inches with the height of each boss being approximately .80 inches]. The temperature gradiant across the width of the gas side (surface 10) of the wall 34, rather than being a variable distribution with the highest temperature at the centerline 61 of surface 10, as for an in-line arrangement, is now found to be more uniform and flat but less symmetrical. The amount of offset 60 of a spark plug terminal (viewed as the intersection of axes 47 and 48 for each boss in FIG. 1) is important. The offset 60 is a dimension that should be viewed with reference to the centerline 61 of the surface 10; it must preferably be less than a radius of a boss to achieve the benefits of this invention. | A rotary internal combustion engine is disclosed having circumferential type cooling circuit for the rotor housing and a plurality of spark plugs extending through the trochoid wall of the rotor housing at a vertically rising zone of said circuit. The plugs are contained by bosses extending through the coolant flow passage; the bosses are arranged to stagger the up-stream sides of said bosses with respect to controlled flow of coolant thereabout, thereby increasing flow control, increasing heat transfer, and preventing a collection of vapor which may act as an insulation film hindering heat transfer between said bosses and coolant flow. The centerline of said bosses are preferably skewed with respect to both a plane bisecting the flow longitudinally and a plane bisecting the flow transversely, whereby the spark terminals of said plugs may be maintained within narrow offset limits on opposite sides of a centerline of the gas side of said trochoid wall. | 5 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to the manufacture of semiconductor memories, and in particular, directed to a split-gate flash memory having an increased coupling ratio of source to floating gate through a judicious tilt angle implanting in a trench source with tilted walls, and to a method of forming of the same.
(2) Description of the Related Art
Normally, a high degree of coupling is desired between the source and the floating gate of a split-gate flash memory cell in order to provide enhanced erasing and programming speed, as is known in the art. If the high degree of coupling is sought by higher implant energy, then the floating gate gets damaged. If, on the other hand, the increase in the coupling ratio is attempted by increasing the lateral diffusion of the implant, then the well-known problems of punch-through and junction breakdown are encountered. These problems are not unique to flat or shallow source regions only. Even with a three dimensional trench but straight walled source regions, same problems are encountered unless additional steps are taken, as disclosed later in the embodiments of the present invention.
Over the years, numerous improvements in the performance as well as in the size of memory devices have been made by varying the simple, basic one-transistor memory cell, which contains one transistor and one capacitor. The variations consist of different methods of forming capacitors, with single, double or triple layers of polysilicon, and different materials for the word and bit lines. In general, memory devices include electrically erasable and electrically programmable read-only memories (EEPROMs) of flash electrically erasable and electrically programmable read-only memories (flash EEPROMs). Many types of memory cells for EEPROMs or flash EEPROMs may have source and drains regions that are aligned to a floating gate or aligned to spacers. When the source and drain regions are aligned to the floating gate, a gate electrode for a select transistor is separate from the control gate electrode of the floating gate transistor. Separate select and control gates increase the size of the memory cell. If the source and drain regions are aligned to a spacer formed after the floating gate is formed, the floating gate typically does not overlie portions of the source and drain regions. Programming and erasing performance is degraded by the offset between the floating gate and source and drain regions.
Most conventional flash-EEPROM cells use a double-polysilicon (poly) structure of which the well known split-gate cell is shown in FIG. 1 . Here, two MOS transistors share a source ( 25 ). Each transistor is formed on a semiconductor substrate ( 10 ) having a first doped region ( 20 ), a second doped region ( 25 ), a channel region ( 23 ), a gate oxide ( 30 ), a floating gate ( 40 ), intergate dielectric layer ( 50 ) and control gate ( 60 ). Substrate ( 10 ) and channel region ( 23 ) have a first conductivity type, and the first ( 20 ) and second ( 25 ) doped regions have a second conductivity type that is opposite the first conductivity type.
As seen in FIG. 1, the first doped region, ( 20 ), lies within the substrate. The second doped region, ( 25 ), also lies within substrate ( 10 ) and is spaced apart form the first doped region ( 20 ). Channel region ( 23 ) lies within substrate ( 10 ) and between first ( 20 ) and second ( 25 ) doped regions. Gate oxide layer ( 30 ) overlies substrate ( 10 ). Floating gate ( 40 ), to which there is no direct electrical connection, and which overlies substrate ( 10 ), is separated from substrate ( 10 ) by a thin layer of gate oxide ( 30 ) while control gate ( 60 ), to which there is direct electrical connection, is generally positioned over the floating gate with intergate oxide ( 50 ) therebetween.
In prior art, different methods for increasing the coupling between the source and the floating gate are taught. In U.S. Pat. No. 6,159,801, Hsieh, et al., disclose a three-dimensional source capable of three-dimensional coupling with the floating gate of a split-gate flash memory cell. This is accomplished by first forming an isolation trench, lining it with a conformal oxide, then filling with an isolation oxide and then etching the latter to form a three-dimensional coupling region in the upper portion of the trench. A floating gate is next formed by first filling the three-dimensional region of the trench with polysilicon and etching it. The control gate is formed over the floating gate with an intervening inter-poly oxide. The floating gate forms legs extending into the three-dimensional coupling region of the trench thereby providing a three-dimensional coupling with the source which also assumes a three-dimensional region. The leg or the side-wall of the floating gate forming the third dimension provides the extra area through which coupling between the source and the floating gate is increased. In U.S. Pat. Nos. 6,017,795 and 6,124,609, Hsieh, et al., propose a different split-gate flash memory cell with increased coupling ratio, and the making of the same. Here, the source line is formed in a trench in a substrate over a source region. The trench walls provide the increase source in the coupling.
Kim of U.S. Pat. No. 5,527,727, on the other hand, discloses a method of manufacturing a split-gate EEPROM cell where an active region is defined to include a source bit line and a drain bit line region. A first polysilicon layer is etched through a floating gate mask until a silicon substrate in the source bit line region and the drain bit line region is exposed. A buried N+ layer is formed in the exposed silicon substrate by implanting impurity ions. A thick oxide film is formed on the buried N+ layer by a subsequent oxidation process, and this thick oxide film is etched to a constant thickness by a self-aligned etching process for forming a float gate. Thereafter, a select gate oxide film and a select gate are formed by a general process. Thus, the electrical characteristics of the cell is enhanced by decreasing the topology generated by the oxide film formed in a bit line containing a source region and a drain region, and a bit line is formed containing a source region and a drain region by performing the buried N+ impurity ion implantation process only once.
In addition, fabrication of a non-volatile memory is described by Lee, et al., in U.S. Pat. No. 6,037,221 while Ogura describes the making of a non-volatile random access memory in U.S. Pat. No. 5,780,341.
The present invention discloses still a different method of forming a split-gate flash memory device characterized by a split-gate side (between the control gate and the drain), a stacked-side (between the floating gate and the source) and by a coupling ratio between the floating gate and the source. As is stated earlier, the coupling ratio affects the program speed, that is, the larger the coupling ratio, the faster is the programming speed, and is not a fixed value by virtue of the variability of the channel length and hence that of the overlap between the floating gate and the source. Usually, if channel length is increased through greater lateral diffusion in the source region, punchthrough occurs due to excessive current well below the threshold voltage. It is shown later in the embodiments of the present invention that the coupling ratio can be increased by incorporating a judicious tilt angle implant in a trench source having tilted walls, thus alleviating the punchthrough and junction break-down of the source region.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method of forming a split-gate flash memory with a trench source having an increased coupling to the floating gate.
It is still another object of this invention to provide a method of forming a trench having tilted walls for increased coupling of the source to the floating gate of a split-gate flash memory cell.
It is yet another object of the present invention to provide a split-gate flash memory cell with a trench source having an increased coupling to the floating gate.
It is an overall object of this invention to provide a split-gate flash memory cell having improved programming and erasing speed with a trench source, and also a method of forming the same.
These objects are accomplished by providing a substrate having active and passive regions defined; forming a first gate oxide layer over said substrate; forming a first polysilicon layer over said gate oxide layer; forming a nitride layer over said first polysilicon layer; patterning said nitride layer to expose a portion of said first polysilicon layer to define a floating gate area; performing oxidation of said portion of said first polysilicon layer to form a polyoxide layer over said first polysilicon layer; etching said first polysilicon layer using said polyoxide layer as a hard mask to form a floating gate; forming an interpoly oxide over said polyoxide; forming a second polysilicon layer over said interpoly oxide; patterning said second polysilicon layer to form a control gate; forming a trench source in said substrate; performing a source implant; forming a second gate oxide layer over the inside walls of said trench source; performing a lateral diffusion of said source implant; and performing thermal cycle of said substrate.
These objects are further accomplished by providing a substrate having a source region; a split-gate flash memory cell on said substrate; a trench source in said source region; a gate oxide layer over the inside walls of said trench source; and a laterally enlarged diffused area of said source region.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a conventional split-gate type memory cell of prior art.
FIGS. 2 a - 2 i are top views of a substrate showing the forming of a split-gate flash memory cell of this invention having a trench source with improved coupling to the floating gate.
FIGS. 3 a - 3 i correspond to the top views of FIGS. 2 a - 2 i showing the cross-sections of the substrate of the present invention, specifically:
FIG. 3 a is a cross-sectional view of the substrate of FIG. 2 a showing the forming of first gate oxide layer, according to the present invention.
FIG. 3 b is a cross-sectional view of the substrate of FIG. 2 b showing the forming of a first polysilicon layer, followed by the forming of a nitride layer, and a first photoresist layer, according to the present invention.
FIG. 3 c is a cross-sectional view of the substrate of FIG. 2 c showing the patterning of the first photoresist layer, according to the present invention.
FIG. 3 d is a cross-sectional view of the substrate of FIG. 2 d showing the patterning of the nitride layer, according to this invention.
FIG. 3 e is a cross-sectional view of the substrate of FIG. 2 e showing the forming of the polyoxide caps of the floating gate as well as the floating gate itself, according to the present invention.
FIG. 3 f is a cross-sectional view of the substrate of FIG. 2 f showing the forming of an interpoly oxide layer, comprising a layer of high temperature oxide sandwiched between two layers of thermal oxide, according to the present invention.
FIG. 3 g is a cross-sectional view of the substrate of FIG. 2 g showing, after the forming of the control gates, the forming of the trench source of the present invention, with tilted walls.
FIG. 3 h is a different cross-sectional view of the substrate of FIG. 2 h showing the increased lateral diffusion of the trench source of this invention after annealing of the substrate.
FIG. 3 i is an additional cross-sectional view of the substrate of FIG. 2 i showing the further increase in the lateral diffusion of the trench source of this invention after thermal cycling of the substrate, thereby increasing the coupling ratio between the source and the floating gate, according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, specifically to FIGS. FIGS. 2 a - 2 i , and FIGS. 3 a - 3 i , there is shown a method of forming a split-gate flash memory cell having improved programming and erasing speed with a tilted trench source, and also a structure thereof. FIGS. 2 a - 2 i show a top view of a semiconductor substrate at different steps of the process, while FIGS. 3 a - 3 i show the cross-sectional views of the substrate at the corresponding steps.
Thus, FIG. 2 a shows a top view of a semiconductor substrate ( 100 ) where active regions ( 107 ) and field regions ( 105 ) have been defined. A cross-section through an active region is shown in FIG. 3 a. First, a layer of gate oxide ( 110 ), better seen in the cross-sectional view, is formed over the substrate. This first gate oxide layer may be formed by using chemical vapor deposition (CVD) SiO 2 , or grown thermally. It is preferred that layer ( 110 ) is grown thermally at a temperature between about 800 to 950° C., and to a thickness between about 70 to 90 angstroms (Å)
Next, first polysilicon layer ( 120 ), later to be formed into a floating gate, is deposited over the first gate oxide layer, as shown in FIGS. 2 b and 3 b. Polysilicon is formed through methods including but not limited to Low Pressure Chemical Vapor Deposition (LPCVD) methods, CVD methods and Physical Vapor Deposition (PVD) sputtering methods employing suitable silicon source materials. It is preferred that LPCVD is used with a silicon source SiH 4 at a temperature between about 530 to 650° C. This is followed by forming nitride layer ( 130 ) over the first polysilicon layer. It is preferred that nitride layer is formed by CVD at a temperature between about 650 to 800° C. by reacting dichlorosilane (SiCl 2 H 2 ) with ammonia (NH 3 ) and to a thickness between about 700 to 900 Å. Then, first photoresist layer ( 140 ) is formed and patterned as shown in FIGS. 2 b and 3 b. Openings ( 145 ), where floating gates are defined, can be better seen in the cross-sectional view in FIG. 3 c.
Nitride layer ( 130 ) is then etched. The etch stops on the polysilicon layer, as shown in FIG. 3 d. In the top view in FIG. 2 d, portions of the silicon layer that are exposed at the bottom of the etched openings are shown. At the next step photoresist layer ( 140 ) is removed.
Through the patterned openings in the nitride layer, exposed polysilicon is next oxidized using wet-oxidation at a temperature between about 800 to 950° C. The resulting polyoxide layer, or “caps” ( 125 ), are shown in FIG. 3 e, where the nitride layer is no longer needed and has been wet-stripped in phosphoric acid solution H 3 PO 4 . The polyoxide layer preferably has a thickness between about 1100 to 1300 Å. Using the polyoxide layer as a hard mask, the polysilicon layer is etched, thus forming floating gates ( 120 ) which are shown in FIG. 3 e, and the overlying “caps” ( 125 ) in the top view in FIG. 2 e.
A composite interpoly oxide layer ( 150 ) is next formed over the floating gate as shown in FIG. 3 f. The top view is shown in FIG. 2 f. The composite layer comprises three layers where the first layer is a first thermal oxide which is thermally grown at a temperature between bout 800 to 950° C., and to a thickness between about 30 to 50 Å. The second layer is a high temperature oxide (HTO), deposited to a thickness between about 120 to 140 Å at a temperature between about 800 to 950° C. And the third layer is a second thermal oxide layer, also grown at the same temperature as the first gate oxide layer, but to a thickness between about between about 60 to 80 Å. The preferred total thickness of interpoly oxide layer ( 150 ) in FIG. 3 f is thus between about 210 to 270 Å.
Subsequently, using the same process as in forming the first polysilicon layer, a second polysilicon layer ( 160 ) is formed over the interpoly oxide layer. Then, following the normal process steps of forming and patterning another photoresist layer (not shown) to define the control gate, and etching the second polysilicon layer to form the control gate, a structure is formed as shown in the cross-sectional view in FIG. 3 g. The preferred thickness of the second polysilicon layer is between about 1900 to 2100 Å.
After the removal of the photoresist layer to form the control gates, another second photoresist, layer ( 170 ) in FIGS. 2 g and 3 g, is formed over the control gate to define cell source area. Then, and as a main feature and key aspect of the present invention, the source region is etched to form a trench source. Trench source ( 109 ) is also shown in FIG. 3 g and has a depth between about 220 to 600 Å. It is important, however, that the trench also has tilted walls with an included angle α between about 10 to 45 degrees. Taking advantage of tilted walls, a source implant is performed at its tilt angle between about 10 to 45 degrees with phosphorous ions at a dosage level between about 1×10 15 to 1×10 16 atoms/cm 2 , and energy between about 10 KeV to 50 KeV. Subsequently, a second thermal oxide, layer ( 190 ) in FIG. 3 h, is formed over the tilted walls of the trench source. This is accomplished by thermal growth at a temperature between about 800 to 950° C., and to a thickness between about 60 to 80 Å.
It will be noted, however, that although the coupling range ( 187 ) of the diffusion area ( 185 ) of the trench source, as obtained with the disclosed tilt angles, is wider than the conventional ranges obtained with flat source and implant, it is disclosed here that the range can be improved even further by a subsequent critical step. This involves a further lateral diffusion of implanted ions by annealing the substrate at a temperature between about 800 to 950° C. It is found that the lateral diffusion can be improved even more by subjecting the substrate to thermal cycling as depicted by the reference numeral ( 200 ) in FIG. 3 h. That is, the range of the newly diffused area ( 205 ) spans at least one-half the width of the floating gate, namely, reaching point ( 207 ) as shown in both FIGS. 3 h and 3 i. The cross-sectional views are that of the top views given in FIGS. 2 h and 2 i. The thermal cycle is accomplished between temperatures about 800 and 950.
Thus, the disclosed tilted trench source provides a higher coupling ratio of source to floating gate with lower implant energy than is possible with conventional flat source cells. This is primarily because of the increased lateral diffusion area of the straggle or stray ions assisted by the tilt angle of both the sidewalls of the trench as well as the tilt angle implant of the source, coupled with annealing and thermal cycling which are believed to be lacking in conventional methods.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention. | A split-gate flash memory cell having improved programming and erasing speed with a tilted trench source, and also a method of forming the same are provided. This is accomplished by forming two floating gates and their respective control gates sharing a common source region. A trench is formed in the source region and the walls are sloped to have a tilt. A source implant is performed at a tilt angle and the trench is lined with a gate oxide layer. Subsequently, a lateral diffusion of the source implant is performed followed by thermal cycling. The lateral enlargement of the diffused source is found to increase the coupling ratio of the split-gate flash memory cell substantially. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to a system and a method for controlling the composition for lithography process in real time using a near infrared spectrometer. More particularly, this invention relates to a system and a method for automatically controlling the multi-component composition, such as photoresist, stripper, developer, etchant, thinner, rinser/cleaner and EBR (etch bead remover), which is used in a lithography process for manufacturing a semiconductor device, a liquid crystal display device (LCD) and so on, in real time (on-line) using a near infrared spectrometer.
BACKGROUNDS OF THE INVENTION
[0002] The composition, such as photoresist, stripper, developer, etchant, thinner, rinser/cleaner, EBR (etch bead remover) and so on, is conventionally used in a lithography process for manufacturing a semiconductor device, a LCD device and so on. The composition contains various components such as organic solvent, photoresist component, water, acid component, base component, and so on. As the apparatus for analyzing these components in the composition, a titroprocessor, an ion chromatography, a gas chromatography, a capillary ion analyzer, a moisture analyzer, a UV-Vis spectrometer, a Raman spectrometer and so on are conventionally used. However, it usually takes too much time to analyze the various components in the composition with the conventional apparatuses. In order to reduce the time required for analyzing the various components, more than two apparatuses can be used at the same time. However, even in that case, the real-time analysis of each component cannot be carried out adequately, and therefore it is not easy to improve the time efficiency for analysis. Furthermore, it is difficult to avoid problem when analyzing the compositions with the conventional apparatuses.
[0003] In order to overcome these disadvantages, the method of using an on-line analysis apparatus has been recently developed. However, the present on-line analysis apparatus only performs an automatic sampling, and accordingly cannot sufficiently reduce the required time for analysis, and cannot analyze the various components in real time and at the same time. Namely, it is impossible to obtain the overall information of the analyzed composition in real time, which is required for handling or controlling the composition used in a lithography process. Accordingly, it is required the method, which can analyze in real time the components of the composition used in a lithography process for manufacturing a semiconductor and an LCD device, and which can control the lifespan of the composition, and manage and recycle the composition.
SUMMARY OF THE INVENTION
[0004] Accordingly, it is an object of the present invention to provide a system and a method for controlling the composition for a lithography process in real time using a near infrared spectrometer, which can analyze and control the components such as organic solvent, photoresist component, water, acid component and base component, which is included in the composition for the lithography process, such as photoresist, stripper, developer, etchant, thinner, rinser/cleaner and EBR (etch bead remover).
[0005] It is other object of the present invention to provide a system and a method for controlling the composition for a lithography process, which is capable of simply sampling the multi-component composition for the lithography process.
[0006] It is another object of the present invention to provide a system and a method for controlling the composition for a lithography process, which can improve the process efficiency by transferring or adding a necessary composition with a pump or a vacuum apparatus according to the properties of the composition.
[0007] It is another object of the present invention to provide a system and a method for controlling the composition for a lithography process, which can analyze the multi-component composition without causing any change or degradation in the component thereof, and can reuse or recycle the analyzed composition, and reduce the generation of waste water.
[0008] To achieve these and other objects, the present invention provides a system for controlling a composition for a lithography process in real time, which comprises a composition circulator for withdrawing the composition from a storage tank retaining the composition for a lithography process, and for recycling the withdrawn composition to the storage tank, through a flow cell; a composition analyzer for measuring an absorbance of the composition passing through the flow cell, and for calculating the concentration of at least one component of the composition from the measured absorbance; a component supplier for supplying a deficient component to the storage tank when a concentration of the deficient component is below a predetermined level; and a controller for controlling the component supplier to adjust the concentration of each component of the composition according to the absorbance.
[0009] The present invention provides a method for controlling a composition for a lithography process in real time, which comprises the steps of; transferring a composition in a storage tank for a lithography process to a transfer vessel of a depressurized condition; transferring the composition in the transfer vessel to a flow cell by injecting inert gas to the transfer vessel; measuring a concentration of at least one component of the composition by measuring an absorbance of the composition while the composition passes through the flow cell; recycling the composition from the flow cell to the storage tank; transferring a deficient component of the composition into an addition tank; and supplying the deficient component in the addition tank into the storage tank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A more complete appreciation of the invention, and many of the attendant advantages thereof, will be better understood by reference to the following drawings, wherein:
[0011] FIG. 1 is a block diagram of a composition circulator, which is used in a system for controlling a composition for a lithography process in real time using a near infrared spectrometer according to an embodiment of the present invention;
[0012] FIG. 2 is a block diagram of a composition analyzer and a controller, which are used in a system for controlling a composition according to an embodiment of the present invention;
[0013] FIG. 3 is a flow chart for illustrating the operation of a composition circulator, a composition analyzer and a controller, which are used in a system for controlling a composition according to an embodiment of the present invention;
[0014] FIG. 4 is a block diagram of a component supplier, which is used in a system for controlling a composition according to an embodiment of the present invention; and
[0015] FIG. 5 is a flow chart for illustrating the operation of a component supplier, which is used in a system for controlling a composition according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Preferred embodiments of the present invention will be explained in the following detailed description by reference to the accompanying drawings.
[0017] The system for controlling the composition for a lithography process in real time according to the present invention comprises i) a composition circulator, iii) a composition analyzer, iii) a component supplier and iv) a controller. FIG. 1 is a block diagram of the composition circulator according to an embodiment of the present invention. As shown in FIG. 1 , the composition circulator comprises the first automatic valve V 1 , which is installed on a storage tank 10 retaining the composition for a lithography process, and is used for withdrawing the composition from the storage tank 10 ; a transfer vessel 30 for receiving the composition withdrawn from the storage tank 10 through the first automatic valve V 1 , and for transferring the received composition to a flow cell 70 ; and a vacuum reservoir 50 for vacuumizing the transfer vessel 30 . The vacuum reservoir 50 is vacuumized or is supplied with inert gas such as nitrogen gas. When the vacuum reservoir 50 is vacuumized, the composition is supplied to the transfer vessel 30 from the storage tank 10 . When inert gas is supplied to the vacuum reservoir 50 , the composition is transferred to the flow cell 70 from the transfer vessel 30 due to the pressure of the inert gas, and then the analyzed composition in the flow cell 70 is recycled to the storage tank 10 through the sixth automatic valve V 6 .
[0018] The composition circulator can further include a vacuum ejector 40 for vacuumizing the vacuum reservoir 50 by receiving air and ejecting air therefrom according to the control of the second automatic valve V 2 . The amount of a ir injected into the vacuum ejector 40 can be adjusted by the first regulator R 1 installed between the second automatic valve V 2 and the vacuum ejector 40 . Also, the composition circulator can further include a drain transfer tank 60 , which is connected to the vacuum reservoir 50 , for receiving the composition overflowing from the transfer vessel 30 when the excess amount of the composition is injected into the transfer vessel 30 , and also can further include the fourth automatic valve V 4 for controlling the composition's flow into the drain transfer tank 60 , the fifth automatic valve V 5 for controlling the composition's ejection from the drain transfer tank 60 , the third automatic valve V 3 for injecting inert gas (nitrogen gas) to the vacuum reservoir 50 and the second regulator R 2 for controlling the a mount of nitrogen gas injected into the vacuum reservoir 50 .
[0019] FIG. 2 is a block diagram of the composition analyzer and the controller. As shown in FIG. 2 , ii) the composition analyzer includes the flow cell 70 , through which the composition to be analyzed passes, an optical fiber 12 for irradiating light to the composition for measuring absorbance of the composition, and a near infrared spectrometer 80 for measuring the absorbance of the composition. When the composition is transferred to the flow cell 70 from the transfer vessel 30 , the light from the near infrared spectrometer 80 is irradiated to the composition through the optical fiber 12 . The near infrared spectrometer 80 measures the absorbance of the composition passing through the flow cell 70 , and calculates the concentration of at least one component thereof from the measured absorbance, and then transmits the information about the concentration to the controller 100 . The controller 100 outputs the information about the concentration of the component through an output unit 90 , together with the composition's status such as the “used time” and the “number of use in a lithography process”, which is transmitted from a tank controller 15 . The controller 100 also controls the component supplier to adjust the concentration of each component of the composition, according to the analyzed results of the composition.
[0020] By reference to FIG. 3 , the operation of i) the composition circulator, ii) the composition analyzer and iv) the controller are explained hereinafter. As shown in FIG. 3 , in order to transfer and analyze the composition in the storage tank 10 , firstly, the information about the composition's status such as the “used time” and the “number of use in a lithography process”, is transmitted from the tank controller 15 to the controller 100 (S 10 ). Then, the first automatic valve V 1 , which is connected to the storage tank 10 being currently used, and the second automatic valve V 2 , which is connected to the vacuum ejector 40 , are opened (S 12 ). When the second automatic valve V 2 is opened, the vacuum ejector 40 is vacuumized, and the vacuum reservoir 50 and the transfer vessel 30 are depressurized, and consequently the composition in the storage tank 10 is transferred to the transfer vessel 30 of depressurized condition through the first automatic valve V 1 (S 14 ). In that case, the degree of vacuumization of the vacuum ejector 40 can be adjusted by controlling the amount of the injected air by controlling the first regulator R 1 connected to air injection inlet. According to the degree of vacuumization, the composition is transferred into the transfer vessel 30 slowly or fast. When the excess amount of the composition is injected to the transfer vessel 30 , the excess amount can be ejected therefrom to the drain transfer tank 60 by opening the second and forth automatic valves V 2 , V 4 simultaneously. When the excess amount is injected to the drain transfer tank 60 , the state is detected by a sensor (not shown), and the third, fourth and fifth automatic valves V 3 , V 4 , V 5 are opened, and nitrogen gas is injected. Therefore, the composition in the drain transfer tank 60 is ejected therefrom by the pressure of nitrogen gas.
[0021] When the composition is transferred to the transfer vessel 30 from the storage tank 10 , a lowest-level sensor and a low-level sensor in the transfer vessel 30 operates successively. When the composition is continuously transferred into the transfer vessel 30 , a high-level sensor operates (S 16 ), and the first, second and fourth automatic valves V 1 , V 2 , V 4 are closed (S 18 ). Then, the third and sixth automatic valves V 3 , V 6 are opened (S 20 ), and the composition in the transfer vessel 30 is supplied to the flow cell 70 by the pressure of nitrogen gas injected to the transfer vessel 30 (S 22 ), and the composition transferred to the flow cell 70 is recycled to the storage tank 10 through the sixth automatic valve V 6 . In this process, the rate at which the composition is recycled to the storage tank 10 can be adjusted by controlling the amount of the injected nitrogen gas by using the regulator R 2 installed in nitrogen gas injection inlet. When the low-level sensor of the transfer vessel 30 stops sensing (S 24 ), the third and sixth automatic valves V 3 , V 6 are closed to prevent the flow of the composition (S 26 ). The highest level sensor and the lowest level sensor in the transfer vessel 30 are provided to cope with the operation failure of the high-level sensor and the low-level sensor. As described above, while the composition in the storage tank 10 is passing through a flow cell 70 , the concentration of at least one component of the composition is measured by using a near infrared spectrometer 80 (S 28 ), and the measured concentration of the component is outputted through the output unit 90 , together with the composition's status (S 30 ).
[0022] FIG. 4 is a block diagram of the component supplier used in the system according to an embodiment of the present invention. The component supplier is an apparatus for supplying an additional solution or a deficient component to the storage tank 10 from a separate tank, when the concentration of at least one component of the measured composition is below the predetermined level. As show in FIG. 4 , iii) the component supplier includes one or more automatic valves V 11 , V 12 , one or more addition tanks 130 , 140 for temporarily retaining the composition injected through the automatic valves V 11 , V 12 , and for supplying the retained composition to the storage tank 10 , and a vacuum reservoir 180 for vacuumizing the addition tanks 130 , 140 . The vacuum reservoir 180 is vacuumized, or is supplied with inert gas such as nitrogen gas. In case that the vacuum reservoir 180 is vacuumized, the deficient composition or component is supplied to the addition tanks 130 , 140 from the separate raw material tanks (not shown). In case that the vacuum reservoir 180 is supplied with nitrogen gas, the composition or component to be added is transferred to the storage tank 10 from the addition tanks 130 , 140 due to the pressure of nitrogen gas.
[0023] The component supplier can further include a vacuum ejector 170 for vaccumizing the vacuum reservoir 180 by injecting air thereto and ejecting air therefrom by the control of the seventh automatic valve V 7 . The amount of the air injected into the vacuum ejector 170 can be controlled by adjusting the third regulator R 3 installed between the seventh automatic valve V 7 and the vacuum ejector 170 . Also, the component supplier can further include a drain transfer tank 190 , which is connected to the vacuum reservoir 180 , for retaining the composition overflowing the addition tanks 130 , 140 , in case that the excess composition is injected into the addition tanks 130 , 140 , the ninth automatic valve V 9 for controlling the injection of the excess composition into the drain transfer tank 190 , the tenth automatic valve V 10 for controlling the ejection of the composition from the drain transfer tank 190 , the eighth automatic valve V 8 for injecting inert gas (for example, nitrogen gas) to the vacuum reservoir 180 and the fourth, fifth and sixth regulators R 4 , R 5 , R 6 for controlling the amount of the nitrogen gas injected into the vacuum reservoir 180 . At the end of the addition tanks 130 , 140 , various automatic valves V 13 -V 17 for supplying the composition or component in the addition tanks 130 , 140 to the storage tank 10 can be installed. In addition, a line mixer 160 for mixing the components in addition tanks 130 , 140 and a mixing tank 150 for retaining the mixed solution can be further provided.
[0024] By reference to FIG. 5 , the operation of the component supplier is explained hereinafter. For example, when the concentrations of 2 components of the composition are below their respective predetermined level (S 50 ), the eleventh and twelfth automatic valves V 11 , V 12 are opened (S 52 ), and consequently the deficient components are transferred into the addition tanks 130 , 140 (S 54 ). When a high-level sensor of the addition tanks 130 , 140 operates with the injection of the deficient components (S 56 ), the eleventh, twelfth and seventh automatic valves V 11 , V 12 , V 7 are closed (S 58 ). And the eighth automatic valve V 8 is opened to inject nitrogen gas, and the thirteenth and fourteenth automatic valves V 13 , V 14 are opened (S 60 ) so that each of the adding solution passes through a line mixer 160 by the pressure of nitrogen gas, and consequently each of the adding solution is mixed and injected into the mixing tank 150 (S 62 ), Then, when low-level sensors in the addition tanks 13 , 14 are switched off (S 64 ), the thirteenth and fourteenth automatic valves V 13 , V 14 are closed (S 66 ), and the fifteenth automatic valve V 15 is opened (S 68 ), and the adding solution in the mixing tank 150 is supplied to the storage tank 10 by the pressure of nitrogen gas (S 70 ). According to the same method as described above, 3 or more compositions can be mixed and supplied by increasing the number of the addition tank to 3 or more. The rate at which the adding solution is transferred can be adjusted by controlling regulators R 3 to R 6 installed in an air injection inlet or a nitrogen gas injection inlet.
[0025] In the present invention, i) the composition circulator, ii) the composition analyzer, iii) the controller and iv) the component supplier can be manufactured in an independent cabinet device, respectively, and accordingly can be readily equipped in the existing or new process facilities. Also, by using only ii) the composition analyzer and iv) the component supplier, the function of measuring the concentration of the composition and the function of supplying the deficient components can be carried out in a simple manner. The cabinet, the tank, the automatic valves, the transfer vessel, the necessary line and so on, which constitutes the system of the present invention, can be made of stainless still such as SUS, polyvinylchloride (PVC), polyethylene (PE) and Teflon, according to the properties of the composition. In addition, a pump or a vacuum apparatus can be selectively used according to the properties of the composition to transfer the composition. When successively analyzing two or more compositions in two or more tanks, analysis can be performed time-effectively in real time by only receiving the information of currently analyzed tank from the tank controller 15 . Also, in the present invention, only one near infrared spectrometer 80 , one output unit 90 and one controller 100 can be used for two or more flow cells 70 for respectively receiving different compositions, which reduces the cost of equipment.
[0026] The system of the present invention preferably further equipped with a leakage sensor for sensing the leakage of the composition, for example, due to the problem on a joint part of Teflon tube or any other reason. By installing the leakage sensor, the stability of the system can be improved. In addition, various alarms for alarming the problem on sensors, concentrations of components of analyzed composition, concentrations of impurities, malfunction of the near infrared spectrometer, and so on, can be readily equipped on the system of the present invention. The alarm signals can be transmitted to the tank controller 15 , and be checked by a user in a separate control room.
[0027] As described above, the system and the method for controlling the composition for a lithography process of the present invention, (1) do not cause any change or degeneration in the analyzed composition, (2) can analyze two or more components with one flow cell and can analyze the various compositions by using two or more flow cells, (3) do not require several conventional analysis apparatuses, and do not generate waste water because the system can analyze the multi-component composition with a near infrared spectrometer, (4) can selectively analyze the composition in the currently used tank in a lithography process, and can manage the composition's status, and (5) can transfer the composition either by a pump or a vacuum apparatus according to the property of the analyzed composition. | A system and a method for controlling the multi-component composition such as photoresist, stripper, developer, etchant, thinner, rinser/cleaner and etch bead remover, for a lithography process, which is used for manufacturing a semiconductor device, a liquid crystal display device and so on, are disclosed. The system includes a composition circulator for withdrawing the composition from a storage tank retaining the composition for a lithography process, and for recycling the withdrawn composition to the storage tank, through a flow cell; a composition analyzer for measuring an absorbance of the composition passing through the flow cell, and for calculating the concentration of at least one component of the composition from the measured absorbance; a component supplier for supplying a deficient component to the storage tank when a concentration of the deficient component is below a predetermined level; and a controller for controlling the component supplier to adjust the concentration of each component of the composition according to the absorbance. | 8 |
CROSS-REFERENCE TO PROVISIONAL APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/250,299 entitled, “SUBSTRATE POLISHING DEVICE AND METHOD,” to Edward M. Yokley, filed on Nov. 29, 2000; U.S. Provisional Application No. 60/295,315 entitled, “A METHOD OF ALTERING PROPERTIES OF A POLISHING PAD AND SPECIFIC APPLICATIONS THEREFOR,” to Yaw S. Obeng and Edward M. Yokley, filed on Jun. 1, 2001; and U.S. Provisional Application No. 60/304,375 entitled, “A METHOD OF ALTERING PROPERTIES OF A THERMOPLASTIC FOAM POLISHING PAD AND SPECIFIC APPLICATIONS THEREFOR,” to Yaw S. Obeng and Edward M. Yokley, filed on Jul. 10, 2001, which are commonly assigned with the present invention and incorporated herein by reference as if reproduced herein in its entirety.
TECHNICAL FIELD OF THE INVENTION
The present invention is directed to polishing pads used for creating a smooth, ultra-flat surface on such items as glass, semiconductors, dielectric/metal composites, magnetic mass storage media and integrated circuits. More specifically, the present invention relates to grafting and preserving the grafted surface of polymers, preferably thermoplastic foam polymers, thereby transforming their mechanical and chemical properties to create more suitable polishing pads therefrom.
BACKGROUND OF THE INVENTION
Chemical-mechanical polishing (CMP)is used extensively as a planarizing technique in the manufacture of VLSI integrated circuits. It has potential for planarizing a variety of materials in IC processing but is used most widely for planarizing metallizied layers and interlevel dielectrics on semiconductor wafers, and for planarizing substrates for shallow trench isolation.
In trench isolation, for example, large areas of field oxide must be polished to produce a planar starting wafer. Integrated circuits that operate with low voltages, i.e., 5 volts or less, and with shallow junctions, can be isolated effectively with relatively shallow trenches, i.e., less than a micron. In shallow trench isolation (STI) technology, the trench is backfilled with oxide and the wafer is planarized using CMP. The result is a more planar structure than typically obtained using LOCOS, and the deeper trench (as compared with LOCOS) provides superior latch up immunity. Also, by comparison with LOCOS, STI substrates have a much reduced “birds' beak” effect and thus theoretically provide higher packing density for circuit elements on the chips. The drawbacks in STI technology to date relate mostly to the planarizing process. Achieving acceptable planarization across the full diameter of a wafer using traditional etching processes has been largely unsuccessful. By using CMP, where the wafer is polished using a mechanical polishing wheel and a slurry of chemical etchant, unwanted oxide material is removed with a high degree of planarity.
Similarly, integrated circuit fabrication on semiconductor wafers require the formation of precisely controlled apertures, such as contact openings or “vias,” that are subsequently filled and interconnected to create components and very large scale integration (VLSI) or ultra large scale integration (ULSI) circuits. Equally well known is that the patterns defining such openings are typically created by optical lithographic processes that require precise alignment with prior levels to accurately contact the active devices located in those prior levels. In multilevel metallization processes, each level in the multilevel structure contributes to irregular topography. In three or four level metal processes, the topography can be especially severe and complex. The expedient of planarizing the interlevel dielectric layers, as the process proceeds, is now favored in many state of the art IC processes. Planarity in the metal layers is a common objective, and is promoted by using plug interlevel connections. A preferred approach to plug formation is to blanket deposit a thick metal layer on the interlevel dielectric and into the interlevel windows, and then remove the excess using CMP. In a typical case, CMP is used for polishing an oxide, such as SiO 2 , Ta 2 O 5 , W 2 O 5 . It can also be used to polish nitrides such as Si 3 N 4 , TaN, TiN, and conductor materials used for interlevel plugs, such as W, Ti, TiN.
CMP generally consists of the controlled wearing of a rough surface to produce a smooth specular finished surface. This is commonly accomplished by rubbing a pad against the surface of the article, or workpiece, to be polished in a repetitive, regular motion while a slurry containing a suspension of fine particles is present at the interface between the polishing pad and the workpiece. Commonly employed pads are made from felted or woven natural fibers such as wool, urethane-impregnated felted polyester or various types of filled polyurethane plastic.
A CMP pad ideally is flat, uniform across its entire surface, resistant to the chemical nature of the slurry and have the right combination of stiffness and compressibility to minimize effects like dishing and erosion. In particular, there is a direct correlation between lowering Von Mises stress distributions in the pad and improving polishing pad removal rates and uniformity. In turn, Von Mises stresses may be reduced though the controlled production of pad materials of uniform constitution, as governed by the chemical-mechanical properties of the pad material.
CMP pad performance optimization has traditionally involved the empirical selection of materials and use of macro fabrication technologies. For example, a pad possessing preexisting desirable porosity or surface texture properties may be able to absorb particulate matter such as silica or other abrasive materials. Or, patterns of flow channels cut into the surface of polishing pads may improve slurry flow across the workpiece surface. The reduction in the contact surface area effected by patterning also provides higher contact pressures during polishing, further enhancing the polishing rate.
Alternatively, intrinsic microtextures may be introduced into pads by using composite or multilayer materials possessing favorable surface textures as byproduct of their method of manufacture. Favorable surface microtextures may also be present by virtue of bulk non-uniformities introduced during the manufacturing process. When cross-sectioned, abraded, or otherwise exposed, these bulk non-uniformities become favorable surface microtextures. Such inherent microtextures, present prior to use, may permit the absorption and transport of slurry particles, thereby providing enhanced polishing activity without the need to further add micro- or macrotextures.
There are, however, several deficiencies in polishing pad materials selected or produced according to the above-described empirical techniques. Pads made of layers of polymer material may have thermal insulating properties, and therefore unable conduct heat away from the polishing surface, resulting in undesirable heating during polishing. Numerous virgin homogenous sheets of polymers such as polyurethane, polycarbonate, nylon, polyureas, felt, or polyester, have poor inherent polishing ability, and hence not used as polishing pads. In certain instances, mechanical or chemical texturing may transform these materials, thereby rendering them useful in polishing.
However, polyurethane based pads, currently in widespread use, are decomposed by the chemically aggressive processing slurries by virtue of the inherent chemical nature of urethane. This decomposition produces a surface modification in and of itself in the case of the polyurethane pads.
Yet another approach involves modifying the surface of CMP polishing pads materials to improve the wetability of the pad surface, the adhesion of surface coatings, and the application performance of these materials. Plasma treatment of polishing pad materials is one means to functionalize and thereby modify polishing pad surfaces. However, the simple functionalization of pad surfaces by plasma treatment is known to be a temporary effect, with spontaneous loss of functionalization after one to two days. While some success in the preservation of functionalized pad surfaces has been obtained for fluorinated polymeric surfaces, this has not been demonstrated for other polymeric surfaces, and in particular, thermoplastics.
Accordingly, what is needed in the art is an improved process for functionalizing and preserving a semiconductor wafer thermoplastic polishing pad surface, thereby providing a rapid rate of polishing and yet reducing scratches and resultant yield loss during chemical/mechanical planarization.
SUMMARY OF THE INVENTION
To address the deficiencies of the prior art, the present invention, in one embodiment, provides a polymer, preferably thermoplastic foam polymer, comprising a thermoplastic foam substrate having a modified surface thereon and a grafted surface on the modified surface.
In another embodiment, the present invention provides a method for preparing a polymer, preferably a thermoplastic foam polymer. The method comprises the steps of providing a thermoplastic foam substrate, exposing the substrate to an initial plasma reactant to produce a modified surface thereon, and exposing the modified surface to a secondary plasma reactant to create a grafted surface on the modified surface.
Yet another embodiment provides a method of manufacturing a polishing pad. The method comprises providing a thermoplastic foam substrate, and then forming a thermoplastic foam polishing body with a grafted surface by including those steps described above. A polishing pad is then formed from the thermoplastic foam polishing body that is suitable for polishing a semiconductor wafer or integrated circuit using the grafted surface.
In still another embodiment, the present invention provides a polishing apparatus. This particular embodiment includes a mechanically driven carrier head, a polishing platen, and a polishing pad attached to the polishing platen. The carrier head is positionable against the polishing platen to impart a polishing force against the polishing platen. The polishing pad includes a polishing body comprising a material wherein the material is a thermoplastic foam polymer.
The foregoing has outlined, rather broadly, preferred and alternative features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention in its broadest form.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
FIG. 1 illustrates a polishing apparatus, including a polishing pad fabricated using a thermoplastic foam polymer made according to the present invention.
DETAILED DESCRIPTION
Conditions have been discovered for producing a polymer, preferably thermoplastic foam polymer, having desirable polishing properties. The thermoplastic foam polymer, for example, comprises a thermoplastic foam substrate having a modified surface and a grafted surface on the modified surface. This polymer is produced, for example, by subjecting a thermoplastic foam substrate to a first plasma treatment to produce a modified surface, thereby allowing the grafting of various functional groups onto the substrate's modified surface in a second plasma treatment. Such treatments are facilitated using inert gas plasmas such Helium, Neon or Argon. The thermoplastic foam polymers of the present invention may also be produced using more reactive plasma gases, such as oxygen. In certain embodiments, the functional effects of grafting decline over a period of three to twenty days, as determined by water contact angle measurements, while in other embodiments these functional effects are preserved. The polymers of the present invention are ideally suited for use as pads in CMP applications.
It is believed that exposing polymers, such as thermoplastic foam substrates, to an initial plasma reactant creates ruptured single bonds, existing on the polymer surface regime as excited states. Due to the low mobility and limited vibrational degrees of freedom within the polymer matrix, these triplet sites lack the ability to undergo intersystem crossing and return to ground state for short periods of time. Based on the ability of the plasma surface to show large macro effects, excited state sites are likely present in abundance at the modified surface.
The excited state sites generated by exposing polymers, such as thermoplastic foam polymers, to the initial plasma reactant are thought to provide an attractive base on which to selectively graft polymerized numerous inorganic and organic materials. The modified surface of the polymer incorporating such functional groups is designated as a grafted surface. Such grafted surfaces are particularly useful in CMP processes due to the grafting process's ability to introduce very fine hard groups onto the grafted surface, which is then incorporated into a polishing pad. Such pads may enable the use of reduced or no abrasive slurries, which may improve thermal management. Additionally, the grafting process produces thermoplastic foam polymers with certain desirable physical and chemical properties, such as controlled wetability surfaces, and renders such grafted surfaces permanent. Still other thermoplastic foam polymers may contain grafted functional groups that change the nanoscale morphology of a pad surface, while leaving the bulk properties of the thermoplastic polymer relatively intact.
As noted above, polymers, such as thermoplastic polymers are produced according to the present invention by a process whereby a thermoplastic foam substrate is exposed to primary and secondary plasma mixtures introduced into a conventional plasma generating apparatus. In certain embodiments, the thermoplastic foam substrate is preferably composed of polyurethane, polyolefin or polyvinyl esters. Alternative embodiments of the thermoplastic foam substrate may be, for example, polyurea, polycarbonate, aliphatic polyketone, polysulfone, aromatic polyketone, 6,6 nylon, 6,12 nylon or polyamide. In other preferred embodiments, the substrate may be thermoplastic rubber or melt-processible rubber. However embodiments where the substrate is composed of closed-cell polypropylene, polyethylene, crosslinked polyethylene, ethylene vinyl acetate, or polyvinylacetate are also within the scope of the present invention.
One skilled in the art will be familiar with reagents suitable for producing conventional primary plasma mixtures. For instance, conventional mixtures often include noble gases such as Helium, Neon or Argon; or ammonia, oxygen, or water. In the present invention, the plasma treatment is continued in the presence of a secondary plasma mixture to graft various functional groups onto the polymer surface, depending on the secondary plasma reactant used.
One group of such secondary plasma reactants are oxygen-containing organometallic reactants that produce a grafted surface that includes an inorganic metal oxide. In such embodiments, the secondary plasma mixture typically includes a transition metal such as titanium, manganese, or tantalum. However, any metal element capable of forming an oxygen containing organometallic compound and capable of being grafted to the polymer surface is suitable. Silicon may also be employed as the metal portion of the organometallic secondary plasma mixture. In these embodiments, the organic portion of the organometallic reagent may be an ester, acetate, or alkoxy fragment. The secondary plasma reagent may optionally include ozone, alkoxy silanes, water, ammonia, alcohols, mineral sprits or hydrogen peroxide. For example, in preferred embodiments, the secondary plasma reactant may be composed of titanium esters, tantalum alkoxides, including tantalum alkoxides wherein the alkoxide portion has 1-5 carbon atoms; manganese acetate solution in water; manganese alkoxide dissolved in mineral spirits; manganese acetate; manganese acetylacetonate; aluminum alkoxides; alkoxy aluminates; zirconium alkoxides, wherein the alkoxide has 1-5 carbon atoms; alkoxy zirconates; magnesium acetate; and magnesium acetylacetonate. Other embodiments are also contemplated for the secondary plasma reactant, for example, alkoxy silanes and ozone, alkoxy silanes and ammonia, titanium esters and water, titanium esters and alcohols, or titanium esters and ozone.
Another group of secondary plasma reactants produce grafted surfaces having super hydrated, controlled wetability, and designed alkalinity surface properties. For example, in preferred embodiments, the secondary plasma reactant may be composed of water, aliphatic alcohols, or aliphatic polyalcohols. In other embodiments, the secondary plasma reactant may be hydrogen peroxide, ammonia, or oxides of nitrogen. Yet other embodiment include hydroxylamine solution, hydrazine, sulfur hexafluoride as the secondary plasma reactant. One skilled in the art, however, will recognize that other similar materials, including other organic alcohols or polyalcohols, may produce these desired surface properties when grafted onto the polymer's surface, and thus, are within the scope of the present invention.
Yet another group of secondary plasma reactants result in organic grafted surfaces. For example, in preferred embodiments, the secondary plasma reactant may be composed of allyl alcohols; allyl amines; allyl alkylamines, where the alkyl groups contain 1-8 carbon atoms; allyl ethers; secondary amines, where the alkyl groups contain 1-8 carbon; alkyl hydrazines, where the alkyl groups contain 1-8 carbon atoms; acrylic acid; methacrylic acid; acrylic acid esters containing 1-8 carbon atoms; methacrylic esters containing 1-8 carbon atoms; or vinyl pyridine, and vinyl esters, for example, vinyl acetate.
The conditions of plasma treatment via Radio Frequency Glow Discharge (RFGD) must be carefully chosen to avoid damaging the grafted layer, and to achieve long-lasting grafts. For example, high power plasmas may cause polymer surfaces to crack. See e.g., Owen, M. J. & Smith, P. J. in POLYMER SURFACE MODIFICATION: RELEVANCE TO ADHESION, 3-15 (K. L. Mittal, ed., 1995), incorporated herein by reference as if reproduced herein in its entirety. As further illustrated in experiments described below, the exact grafting conditions depend on factors including the type of polymer specimen, radio frequency and power, and the identity of the primary and secondary plasma reactants. However, typical preferred plasma-grafting process conditions include exposing the thermoplastic foam substrate to a primary plasma reactant treatment time (TT-1) from about 30 s to about 30 min, in a reaction chamber having a pressure ranging from about 130 to about 340 mTorr, and plasma back pressure (PBP) ranging from about 140 to about 200 mTorr. Subsequent exposure of the modified substrate surface to the secondary plasma reactant for similar treatment times (TT-2) and pressures also include a diluting inert gas, where the inert gas to secondary plasma reactant ratio typically ranges from about 1:1 to about 3:1, the dilutant inert gas being introduced into the reaction chamber at a flow rate of about 0.03 to about 1.0 standard liters per min (SLM). The amount of secondary reactant monomer in the gas stream is governed by the monomer vapor pressure (MBP), and the monomer reservoir temperature (MRT), typically ranging from about 20 to about 75° C. The resulting pressure in the reaction chamber during grafting (GP) may range from about 135 to about 340 mTorr, and out gas back pressure (OGBP)may range from about 55 to 70 mTorr. Throughout, the RDGD electrode may be maintained at a constant value within the range of room temperature to about 100° C. One of ordinary skill in the art understands that conditions outside of the above-cited ranges may also be used to produce the subject matter of the present invention.
Polishing pads in certain embodiments of the present invention may be manufactured by first melting a thermoplastic polymer pellets in an extrusion apparatus such as a melt extruder, and blowing gas into the melt to form a thermoplastic foam substrate. The substrate may be formed into pads by techniques well known to those skilled in the art, such as laser cutting or die cutting. The substrate is next formed into a thermoplastic foam polishing body by first exposing the substrate to an initial plasma reactant to produce a modified surface and then exposing the modified surface to a secondary plasma reactant to create a grafted surface on the modified surface. Finally, the polishing body may be incorporated into a pad such that the grafted surface is suitability situated to polish a semiconductor wafer or integrated circuit.
Polishing pads may be employed in a variety of CMP polishing apparatus 150 , one embodiment of which is displayed in FIG. 1 . The thermoplastic foam polymers of the present invention may be incorporated into a polishing body 100 that includes a base pad 110 , where a thermoplastic foam polymer 120 forms a polishing surface located over the base pad 110 . Optionally, a first adhesive material 130 , such as acrylate-based, silicone-based, epoxy or other materials well known to those skilled in the art, may be used to couple the base pad 110 to the thermoplastic foam polymers 120 . The polishing pads thus formed may also have a second adhesive material 140 , well known to those skilled in the art, applied to the platen side. The polishing pad may then be cleaned and packaged for use.
With continuing reference to FIG. 1, the polishing body 100 may then be employed in a variety of CMP processes by incorporation into a polishing apparatus 150 . The polishing apparatus 150 typically includes a conventional mechanically driven carrier head 160 , a conventional carrier ring 170 , a conventional polishing platen 180 , and a polishing pad that includes the polishing body 100 comprising the thermoplastic foam polymer 120 of the present invention, attached to the polishing platen 180 , optionally using the second adhesive 140 . The substrate to be polished 185 , typically a wafer, may be attached to the carrier ring with the aid of a third a conventional adhesive 190 . The carrier head 160 is then positioned against the polishing platen 180 to impart a polishing force against the polishing platen 180 , typically a repetitive, regular motion of the mechanically driven carrier head 160 , while providing an appropriate conventional slurry mixture. Optionally, in certain embodiments of the thermoplastic foam polymer 120 , the slurry may be omitted.
With continuing reference to FIG. 1, in such polishing processes, a substrate 185 may be polished by positioning the substrate 185 , having at least one layer, on to the above-described polishing apparatus 150 , and polishing the layer against the thermoplastic foam polymer 120 of the present invention. In one embodiment, the substrate 185 has at least one layer of material that is a metal layer. In particular embodiments, the metal layer may be is copper or tungsten. In another embodiment, the substrate 185 may be a silicon, polysilicon or dielectric material located on a semiconductor wafer. Thermoplastic foam polymers 120 of the present invention are particularly suited for polishing in shallow trench isolation (STI), interlevel dielectrics, and metal interconnects in integrated circuit fabrication or other fabrication techniques where large areas of field oxide, other dielectrics or metal must be removed from the wafer to produce a planar surface prior to subsequent processing. The thermoplastic foam polymers 120 of the present invention are also desirable for polishing metalization materials such as W, Ti, Cu, Al, and other metals as well as nitrides or barrier materials such as Si 3 N 4 . TaN, TiN.
Experiments
Measurements of solvent contact angles provides a particularly useful means to measure to extent and stability of grafts providing controlled wetability surfaces. Wetability, typically measured by measuring the contact angle of a water droplet, provides an indication of surface energy. A hydrophilic surface having a high surface energy will have a low contact angle. Thermoplastic foam polymers made according to the present invention were examined for changes in water contact angle, by comparing pre- and post-plasma treatment angles, typically for several days following plasma treatment, using commercial instruments (Rame-Hart Goniometer, Mountain Lakes, N.J.; and Accu-Dyne-Test Marker Pen, Diversified Enterprises, Claremont, N.H.).
Several such experiments were performed using approximately 2″ by 2″ sheets of 0.125″ thick thermoplastic elastomer foam (Santoprene® D-40; Advanced Elastomer Systems, LP, Akron, Ohio). The Santoprene® D-40 sheets were manually cleaned with an aqueous/isopropyl alcohol solution, and then placed in the reaction chamber of a conventional commercial RFGD plasma reactor having a temperature controlled electrode configuration (Model PE-2; Advanced Energy Systems, Medford, N.Y.).
In one experiment, for comparison purposes, plasma treatment consisted of exposing the Santoprene® D-40 substrate to only a primary plasma reactant, comprising Helium:Oxygen, 60:40, for 10 minutes, with the reaction chamber maintained at 230 mTorr pressure, the electrode temperature maintained below about 100° C. and using a RF operating power of 2500 Watts. Surface modification was confirmed by the observation of an increased hydrogen and oxygen content to a depth of 100 Angstroms, as measured by Electron Spectroscopy Chemical Analysis (ESCA).
While the pre-treatment water contact angle of the Santoprene® D-40 substrate was 98°, the immediate post-treatment angle was 25°. The contact angle, however, subsequently rose to and stabilized at 60° by 6 days after treatment. Similar results were obtained in a second experiment, when the Santoprene® D-40 substrate was exposed to a primary plasma reactant of 100% ammonia. The water contact angle was 40° immediately following plasma treatment, but progressively rose to and stabilized at 80° by 6 days post-treatment.
In a third experiment, the plasma treatment of the Santoprene® D-40 substrate was commenced by introducing the primary plasma reactant, Argon, for 30 seconds within the reaction chamber maintained at 350 mTorr. The electrode temperature was maintained at 30° C., and an RF operating power of 300 Watts was used. Subsequently, the secondary reactant was introduced for either 10 or 30 minutes at 0.10 SLM and consisted of either Tetraethoxy Silane (TEOS), Titanium Alkoxide (TYZOR), Allyl-Alcohol (Allyl-OH), or Allyl-Amine (ALLYL-NH 2 )vapor mixed with He or Ar gas (TABLE 1). In this, and analogous experiments described below, the amount of secondary reactant in the gas stream was governed by the vapor back pressure (BP) of the secondary reactant monomer at the monomer reservoir temperature (MRT; 50±10° C.). The monomer-carrier gas mixture was further diluted with a separate stream of either argon or helium in the reactor chamber. The pre-and post-plasma treatment water contact angles, shown in TABLE 1, reveal substantially lower immediate post-treatment contact angles as compared to previously described Santoprene® D-40 substrates treated with the primary plasma reactant only.
TABLE 1
Immediate
Seven Day
Pre-
Post-
Post-
Secondary
Treatment
Treatment
Treatment
Plasma
Contact
Contact
Contact
Reactant
TT-2 (min)
Angle (°)
Angle (°)
Angle (°)
TYZOR
10
98
0
36
TYZOR
30
98
0
65
TEOS
30
98
0
90
Allyl-OH
30
98
0
90
Allyl-NH 2
30
98
65
75
Similar results were obtained in a fourth experiment, where Santoprene® D-40 was exposed to a primary plasma reactant of Argon mixture for 30 second at 100 mTorr and 50 Watts RF power, with the electrode maintained at 40° C., and was exposed to a secondary plasma reactant of 100% ammonia. The pre-treatment water contact angle of 98° was reduced to 40° immediately following treatment, with the angle increasing to and stabilizing at 60° by 6 days post-treatment.
In a fifth experiment using Santoprene® D-40 as the substrate, plasma treatment was commenced by introducing the primary plasma reactant, Helium, for 10 minutes with the reaction chamber maintained at 350 mTorr pressure, the electrode temperature below about 100° C. and RF operating power of 3500 Watts was used. This was followed by a second 10 minute plasma treatment under the same conditions while introducing a secondary plasma reactant containing tetraethoxyorthosilicate at 0.10 SLM into the gas stream. The immediate post-treated surface modified thermoplastic foam substrate had a water contact angle of 0°, as compared to 92° for the pre-treated substrate.
In a sixth experiment, 1 inch by 1 inch sheets of 0.063 inch thick cross-linked polypropylene foam (type TPR, from Merryweather Foams Inc., Anthony, N. Mex.) was plasma treated under the same conditions as described for Experiment 5. The immediate post-treated surface modified thermoplastic foam substrate had a water contact angle of 0°, as compared to 90° for the pre-treated substrate.
By careful manipulation of the plasma treatment conditions, the grafts can be preserved for longer periods, as indicated by the stability of water contact angle changes. This is illustrated by a seventh series of experiments conducted on the above-described polypropylene sheets having dimensions of 6 inch by 6 inch by 0.125 inch thickness, under the plasma treatment conditions presented in Table 2. Cold BP (Cold Back Pressure) is measured with the RF power off, while PBP (Power Back Pressure) is with the RF power on. In experiments 12 and 13, PBP was not recorded (n.r.).
TABLE 2
Ar
dilutant
Flow
Cold
Grafting
Sample
TT-1
OGBP
Rate
BP
PBP
GP
MRT
RF Power
Number
(min)
(mTorr)
(SLM)
(mTorr)
(mTorr)
(mTorr)
(° C.)
(Watts)
1
1
60
0.03
120
140
200
50
50
2
1
60
0.03
120
140
300
50
50
3
1
65
0.10
190
207
280
70
50
4
1
65
0.03
120
150
250
50
100
5
1
70
0.03
125
160
320
50
100
6
1
70
0.03
125
160
200
55
100
7
1
60
0.10
180
200
245
50
100
8
1
60
0.10
180
200
340
55
100
9
1
60
0.03
105
125
150
60
50
10
1
55
0.03
105
125
220
50
50
11
1
60
0.01
90
105
130
75
50
12
0
55
0.03
110
n.r.
135
21
50
13
1
55
0.03
110
n.r.
165
60
50
As shown in Table 3, post-treated substrates produced under the conditions described in Table 2 retained their low water contact angles for at least 10 days of exposure to laboratory atmospheric conditions.
TABLE 3
Sample
Pre-treatment
Post-treatment Contact Angle (° )
Number
Contact Angle (° )
0 days
3 days
7 days
10 days
1
90
45
47
50
50
2
90
58
65
67
65
3
90
80
73
73
76
4
90
30
42
45
45
5
90
80
75
75
77
6
90
70
73
73
76
7
90
70
80
75
76
8
90
68
70
75
76
9
90
75
77
77
75
10
90
75
77
77
76
11
90
48
52
59
62
12
90
70
77
75
65
13
90
73
78
75
80
In an eighth experiment, the polishing efficiency of a pad manufactured according to this invention was compared to a conventional polishing pad. A polishing pad was prepared by exposing Aliplast® (JMS Plastic Supplies, Neptune, N.J.; Type 6A: medium foam density and hardness 34 Shore A), a thermoplastic heat moldable cross-linked polyethylene closed-cell foam, to the above-described grafting process. Specifically, secondary plasma reactants, containing either Allyl-Alcohol, or Allyl-Amine, Tetraethoxy Silane (TEOS), or tetraisopropyl-titanate (TYZOR TPT) monomers, were grafted onto the modified Aliplast® substrate, under conditions similar to Sample number 4 shown in Table 1, to produce pads designated as A32AA, A32AN, A32S, and A32T, respectively. The blanket Copper (Cu) polishing properties of pads fashioned from these polymers were compared to the untreated Aliplast® substrate (designated A32), and to a commercially available IC1000/SUBA IV pad stack (Rodel, Phoenix, Ariz.).
The comparison was performed using an CETR CMP simulator (Center For Tribology, Inc., Campbell, Calif. Conditions for thermal oxide polishing include using a down force of 3 psi; table speeds of 0.8 m/min; and a conventional slurry comprising K1501 and polishing time of 5 min. Conditions for copper polishing include using a down force of 3 psi; table speeds of 0.8 m/min; and a conventional slurry comprising Cabot EP-5001 containing 3% hydrogen peroxide and adjusted to a pH of about 4, and polishing time of 5 min. Plasma Enhanced Tetraethylorthosilicate (PE-TEOS) 5,000 Å wafers having a deposited 20,000 Å copper surface and an underlying 250 Å thick tantalum barrier layer were used for test polishing.
Cu removal rates for the A32AA, A32AN and A32T pads were about 10,000; 7,500; and 7,200 Å/min, respectively. The corresponding Ta removal rates were only 216, 215 and 175 Å/min, respectively. In comparison, the untreated A32 pad removed Cu at a rate of about 3,200 Å/min. The high selectivity of the grafted Aliplast® pads for Cu polishing compared to Tantalum (Ta) polishing may be expressed by the ratio of Cu to Ta removal rates. For the A32AA, A32AN and A32T pads, the selectivity ratio was about 46, 35 and 41, respectively. In comparison, the Cu and Ta removal rates of an IC1000/SUBA IV pad stack were about 5,700 Å/min and about 170 Å/min, respectively, giving a Cu:Ta selectivity of about 34.
Although the present invention has been described in detail, those skilled in the art should understand that they can make various changes, substitutions and alterations herein without departing from the spirit and scope of the invention in its broadest form. | The present invention is directed, in general, to an improved material and method of planarizing a surface on a semiconductor wafer and, more specifically, to a method of altering the properties of polymers, preferably thermoplastic foam polymers, used in polishing applications. The chemical and mechanical properties thermoplastic foam substrates can be transformed by inorganic, inorganic-organic, and or organic—organic grafting techniques, such that the polymer foam is endowed with new set of properties that more desirable and suitable for polishing. | 1 |
BACKGROUND OF THE INVENTION
This invention generally relates to structural reinforcement devices, and in particular to fasteners used to secure a frame member to a foundation.
Buildings and other structures are exposed to natural occurrences such as earthquakes, tornados, hurricanes and high winds which can cause damage when design loads are exceeded. Typically, damage results from either shear forces, which pull or tear apart a portion of a building, or uplifting forces, which cause separation of a structural frame of the building from its foundation. In an effort to prevent damage from shear forces, the structural frame is commonly braced or reinforced. Several approaches are explained in Hardy U.S. Pat. Nos. 6,148,583, 6,067,769 and 5,729,950.
In an effort to prevent damage from uplifting forces, the structural frame is commonly secured to the foundation using a plurality of fasteners. Building codes typically specify the required fastener length and diameter as well as their placement within the foundation. Typically, these fasteners are vertically oriented, metallic anchor bolts which extend through the structural frame and into a foundation material. An anchor bolt consists of two ends; a stud and an anchor portion. The stud, which has a threaded end, protrudes above the concrete for use in fastening a building frame to the foundation using a standard threaded nut and washer assembly. The anchor portion is commonly configured in a “J” or “L” located within the foundation to secure the bolt in the foundation. In addition, eye bolts, “U” bolts, headed bolts or headed bolts with washers are sometimes used.
The effectiveness of the anchor bolt in preventing damage is dependent on its own strength, the type of foundation material in which the anchor portion is set and the connection between the foundation material and anchor portion. The connection between the foundation material and anchor portion is established by the configuration of the anchor portion. The configurations of conventional anchors vary substantially and are dependent on whether the anchor was designed to be installed prior to or after the laying of the foundation material. Anchor portions designed to be installed after the foundation material is laid are typically bonded into holes which are pre-drilled into an existing foundation. Anchor bolts designed to be set into position prior to pouring the foundation material are usually placed into position by affixing each bolt to a metal or wooden support using bailing wire. These anchor portions are embedded in the foundation. As a result, anchor bolts with anchor portions embedded in the foundation have a substantially greater tensile capacity compared to those installed after the foundation is laid.
Unfortunately, the capability of an embedded anchor bolt to provide tensile strength to a frame member is degraded if the anchor bolt is not positioned properly, becomes misaligned during the pouring of the foundation or does not adequately penetrate the foundation. Moreover, the stud may protrude through the foundation at the wrong position making it difficult to secure the structural frame to the foundation and compromising its effectiveness. Further, the tasks of positioning and securing each anchor bolt to the support are time consuming, labor intensive and correspondingly costly.
SUMMARY OF THE INVENTION
Accordingly, among the several objects of the present invention is the provision of a fastener capable of effectively fastening a frame member of a building or other structure to a foundation; the provision of such a fastener which can be accurately and securely positioned in the foundation; the provision of such a fastener which is easily positioned in the foundation; and the provision of such a fastener capable of reducing installation costs.
A fastener constructed according to the present invention is for use in securing the frame member to the foundation. Generally, the fastener comprises a plurality of elongate studs disposed in spaced-apart relation to one another for connection to the frame member. At least a portion of the studs are disposed generally in a stud plane. Each stud has a first and second free ends. An anchor portion is connected to the studs away from the first ends and extending outwardly from the stud plane. The anchor portion is adapted to secure the fastener in the foundation.
In another aspect, the fastener comprises the plurality of elongate studs that are disposed in spaced-apart relation to one another for connection to the frame member and have a central longitudinal axes. Each stud has the first and second free ends. An anchor portion is connected to the studs away from the first ends and extending outwardly from the central longitudinal axes of the studs. A receiving element of the fastener is adapted to receive a positioner for positioning the fastener within the foundation.
In yet another aspect, a one-piece fastener comprises two elongate studs disposed in spaced-apart relation to one another for connection to the frame member with at least a portion of the studs being disposed generally in a stud plane. Each stud has a first free end with threads thereon and a second end. An anchor portion connected to the second ends of the studs interconnects the studs and extends outwardly at an angle of at least about 20° from the stud plane. The anchor portion includes an opening adapted to receive the positioner for positioning the fastener within the foundation.
Other objects and features of the present invention will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective illustrating an anchor bolt of the present invention embedded in a concrete foundation and securing a frame structure, with parts broken away to show details;
FIG. 2 is a perspective of the anchor bolt of FIG. 1 stabilized using a positioner and a template;
FIG. 3 is a perspective illustrating the anchor bolt of FIG. 1 stabilized using an alternative employment of the positioner and template;
FIG. 4 is a left side elevation of the anchor bolt of FIG. 1 ;
FIG. 5 is a front elevation of the anchor bolt of FIG. 1 ;
FIG. 6 is a top plan view illustrating the anchor bolt of FIG. 1 ; and
FIG. 7 is a right side elevation illustrating an anchor bolt having a 45 degree bend.
Corresponding reference characters indicate corresponding parts throughout the views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and in particular to FIG. 1 , a fastener according to the present invention embedded in a foundation F is indicated generally. Also shown are several fragments of other studs. The fastener positively secured framing members, such as framing member 3 , of buildings or other engineered structures to resist shear and uplifting forces. Only a small fragment of the framing member 3 is illustrated in FIG. 1 . Another suitable framing member is the commercially available Hardy Frame System manufactured by Hardy Frames, Inc. of Ventura, Calif. The fastener 1 is embedded in a foundation F of a suitable material such as concrete. The framing member 3 is secured to ends of the fastener 1 which protrude above the foundation F, using a standard washer 7 and nut 9 .
The fastener 1 is a generally U-shaped, cylindrical rod further modified by bending the base of the U outwardly. In one embodiment the cylindrical rod has a diameter of ⅞-inches. Two linear arms of the U are the studs 11 , 13 in the illustrated embodiment. The base of the U which extends outwardly defines an anchor portion 15 in the illustrated embodiment. Welded to the anchor portion is a receiving element or ring 17 , the purpose for which is further described below. The studs 11 , 13 , anchor portion 15 and ring 17 comprise a one-piece assembly. The fastener 1 is constructed of a suitable material such as a rod of either steel or high tensile capacity steel.
The two studs 11 , 13 are located substantially in a common plane P (see FIGS. 4–6 ) with the distance D between each stud varying depending on intended use. However, the studs 11 , 13 could be other than coplaner without departing from the scope of the present invention. In the preferred embodiments, the studs 11 , 13 are set at either 8½-inches, 14½-inches or 20½-inches apart. Each stud 11 , 13 comprises a threaded end 19 and a shank 21 . The threaded end, which is opposite from the anchor portion 15 , is used to secure the framing member 3 to the foundation F using the washer 7 and nut 9 ( FIG. 1 ). In one embodiment, the threaded end 19 has a nominal length of 5 inches. However, the threaded end 19 can be set to any length suitable for a particular application. Beneath the threaded end 19 is the shank 21 , a straight, cylindrical segment. In one embodiment, the shank 21 has a nominal length of 16 inches which provides the spacing necessary for the threaded end 19 to adequately protrude above the foundation F and the anchor portion 15 to adequately embed in the foundation. It is to be understood that the length of the shank 21 may be other than 16 inches without departing from the scope of this invention.
Immediately below the shank 21 is a bend 23 followed by the anchor portion 15 . The bend 23 can be set to various angles with the two illustrated embodiments being either 45 degrees ( FIG. 7 ) and 90 degrees ( FIG. 4 ) from the plane P of the studs 11 , 13 . The anchor portion 15 of the fastener 1 has a nominal length of 1½ inches. As a result of the plane change at the bend 23 , the anchor portion 15 has horizontal projection orthoganal to the plane P of the studs 11 , 13 . Thus, the anchor portion 15 is able to laterally penetrate into the foundation F. The anchor portion 15 is arcuate, and a radius of curvature R of the arcuate member can be changed based on its intended use. In certain embodiments of the arcuate member, radii are approximately 4 inches, 6½ inches and 9½ inches.
The ring 17 is welded in a horizontal position near the center of the anchor portion 15 between the studs 11 , 13 . The ring 17 is sized to permit a cylindrical positioning rod 29 to pass through. In one embodiment, the ring 17 is a ⅞ inch washer. The positioning rod 29 , which is made of a suitable material such as steel, is used to stabilize the fastener 1 during the pouring of the foundation F. The positioner 29 passes through the receiving element 17 and is fixed firmly in foundation F. After the foundation is poured but before it cures, the positioner 29 can be removed.
A template 31 , as shown in FIGS. 2 and 3 , is secured to a form board 33 using nails 34 to stabilize the fastener 1 during the pouring and curing of the foundation F. The template. 31 includes holes for receiving each of the threaded ends 19 and the positioner 29 ( FIG. 2 ). The positioner 29 is passed through the center template hole 35 , the ring 17 and fixed firmly in a foundation base 37 of a suitable material such as gravel or soil. In addition, the threaded ends 19 are fastened to the template 31 using a standard washer 7 and nut 9 combination. Alternatively, as shown in FIG. 3 , the template 31 can be used to stabilize the fastener 1 by passing the positioner 29 only through the ring 17 and not center template hole 35 . As before, the threaded ends 19 of the fastener 1 are attached to the template 31 using a washer 7 and nut 9 combination. After the foundation F is poured but before it cures, the positioner 29 can be removed. In still another configuration (not shown), the template 31 can be used to stabilize the fastener 1 without the positioner 29 by fastening the thread ends 19 to the template using a washer 7 and nut 9 combination. Since the template 31 does not come into contact with the foundation F, it can be removed after the foundation has cured.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results obtained.
When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
As various changes could be made in the above without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A fastener includes a plurality of elongate, threaded studs which are connected to a common anchor portion for securing a frame member to a foundation. Attached to the anchor portion is a receiving element adapted to receive a positioner. The studs, anchor and receiving element are a one-piece integral assembly constructed of steel or high tensile strength steel. In addition, the fastener is adapted to receive a template and positioner for stability during the pouring and curing of the foundation. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to computer anti-theft devices, particularly of the type adapted to be engaged to a designated slot formed in a side-wall of the computer housing by a rotatable T-shaped tip (or equivalent) on the one hand, and a safety cable adapted to be tied to a stationary object, on the other hand (hereinafter collectively referred to as “cable locks”).
BACKGROUND OF THE INVENTION
[0002] Numerous types and designs of cable locks are available on the market place, mainly differing only by the type of their locking mechanism employed (keys, push-button, combination, etc.).
[0003] The prime object of the present invention is to extend the protection offered by the conventional locks in the sense that once locked—the removal of computer accessories such as key-board or mouse will be also prevented.
[0004] A further object of the invention is that such extended protection be attained by providing an adaptor, attachable or manipulated by the user before completing the locking operation.
[0005] It is a still further object of the invention that such adaptor be either separate or coupled to the computer lock casing. In the former case, the design of the adaptor should be as much as possible standard in order to fit different models of commercially available cable locks.
SUMMARY OF THE INVENTION
[0006] Thus provided according to a general aspect of invention is an anti-theft locking device of the type comprising a lock casing connectable on the one hand to an immovable object by a safety cable, and on the other hand to the protected object intermediate a designated slot formed in a side wall of the protected object, and a locking mechanism for selectively engaging and disengaging the lock casing to and from said side wall, characterized in that a yoke-member is provided comprising a first portion configured to be, in the engaged state, entrapped between the lock casing and the said side wall, and a second portion bridging over the lock casing and forming an enclosed hollow thereunder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] These and additional constructional features and advantages of the invention will be more fully understood in the light of the ensuing description of several preferred embodiments thereof, given by way of example only, with reference to the accompanying drawings wherein:
[0008] FIG. 1 is a schematic, perspective exploded view, relating to a first preferred embodiment of the invention;
[0009] FIGS. 2 a - 2 d illustrates sequence of stages to complete the mounting of the lock of FIG. 1 ;
[0010] FIG. 3 is a schematic, perspective exploded view relating to a second preferred embodiment of the invention;
[0011] FIGS. 4 a - 4 d illustrate stages of using the lock of FIG. 3 ;
[0012] FIG. 5 is a perspective view of a third preferred embodiment of the invention; and
[0013] FIGS. 6 a - 6 f show stages of completing the engagement of the lock of FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring to FIG. 1 , 10 denotes a portable computer having a side wall 10 a formed with designated slot S as commonly known with respect to most models.
[0015] Further shown is a commercially available combination cable lock 12 . It consists of a safety cable 14 extending from lock casing 16 which is adapted to be tied to a stationary object 18 such as around a table leg.
[0016] In the present example, tip 20 , which needs to be inserted into the slot S and arrested therein, is in the form of detent 22 retractable into the tip 20 once the combination is correctly set (that is by the authorized owner), by manipulating spring urged slider 24 . The retraction of the detent 22 allows the insertion of the tip into the slot S. The locking of the device 12 to the computer housing side wall 10 a is perfected by relieving the slider 24 . The detent resumes its projected position whereby retrieval of the tip 20 from the slot is prevented. The combination wheels are then rotated away from the previous, pre-set arrangement.
[0017] The instant invention proposes to attain additional security, by enabling the arrest of auxiliary equipment operating cables C 1 , C 2 , say, of the mouse and perhaps and additional key-board (not shown).
[0018] This is achieved by providing a yoke-member 30 comprised of a first portion 30 a and a second portion 30 b. The first portion 30 a is ring-shaped having a stepped shoulder, configured to fit over the (circular) proximal portion of the lock casing (see FIG. 2 b ).
[0019] The second portion 30 b is elongated, resembling a bridge which extends from the rim of the ring-shaped first portion upwards, continues parallel to axis of the lock casing and terminates downwards at the distal end thereof, touching the outer surface of the lock casing.
[0020] Obviously, should the lock casing be differently designed regarding its outer contour thereof, the portion 30 a would be designed accordingly.
[0021] The procedure of arresting the cables C 1 and C 2 simultaneously with mounting and locking the device 12 is clearly depicted in FIGS. 2 a to 2 d and need not be explained in greater detail. The major point is that the yoke member 30 , with the cables passing under the arc of the bridging portion 30 b, is arrested between the side-wall 10 a of the computer 10 , and the leading end of the lock casing, and there is no 10 need for additional fastening means.
[0022] Referring now to FIG. 3 (where reference numbers are used with the prefix “1” to denote parts and components corresponding to those of the preceding embodiment), 112 designates a different model of a known combination cable lock. This lock is used in conjunction with an auxiliary component in the form of a roller or wheel 140 . The wheel 140 is integrally formed with a pair pivotable legs 140 a and 140 b (see FIGS. 3 c and 3 d ). The legs are initially in a back-to-back, closed position. By using bolt 142 , the legs 140 a and 140 b can be pushed into a spread—apart position whereby the wheel 140 becomes fastened to the computer side-wall 10 a intermediate the slot S as shown in FIG. 3 a.
[0023] The lock casing 11 z is provided with a latch mechanism which includes a fixed jaw 144 and a slidable jaw 146 displaceable by push-button button 148 . It is thus enabled to engage and disengage the lock-casing to and from the wheel 140 , at will.
[0024] As aforementioned, this type of lock is well known and need not to be described in greater detail.
[0025] Now, according to basic concept of the present invention, there is provided a cable-arresting adaptor in the form of yoke member 130 , having a first portion 130 a and a second portion 130 b. The portion 130 a is so designed as to embrace the outer part the wheel 140 , without interfering with the engagement of the lock casing 112 to the wheel 140 by the jaws 144 and 146 in the normal fashion as shown in FIGS. 4 c and 4 d.
[0026] In operation, the cables C 1 and C 2 are first placed under the arc of the bridging portion 130 b, the member 130 is placed over the wheel 140 , and the lock casing 116 is harnessed to the wheel 140 in the conventional member.
[0027] The third exemplified embodiment of the invention depicted in FIG. 5 does not concern the adaption of conventional cable locks to the novel, additional function of securing auxiliary equipment cable, but to an originally designed product, where the lock casing and the yoke member are permanently coupled to each other.
[0028] Hence, the locking device 212 is provided with a cylinder key operated mechanism 250 (see FIG. 6 b ) of any type know per-se in the art. The lock casing 216 may be made of metal or reinforced plastics. Safely cable 214 is fixed to the lock casing 216 in any suitable manner.
[0029] The yoke member 230 comprises a first portion 230 a and a second, bridge portion 230 b beneath which the protected cables C 1 and C 2 are passed in the operative state of the locking device 212 .
[0030] The bridge portion 230 b may be formed with a bulged, dove-tail extension 232 that fits into a corresponding arcuate slot or cavity 234 when the yoke member is rotated into the cable trapping position, for extra strength (see below).
[0031] The yoke member is rotatable about axle pin 236 .
[0032] The first portion 230 a is formed with a slot 238 and a pair of rounded projections 240 and 240 ′, spaced from each other and configured to fit into the slot S of the computer side wall 210 a.
[0033] As seen in FIG. 6 b, t he locking mechanism (cylinder) 250 , operable by key 252 , is drivingly coupled to stem 254 carrying locking tip 256 , both for displacing the tip against the bias of spring 258 and for rotating same by 90°. Pin 260 is provided for limiting the displacement of the locking cylinder 250 between the extreme positions thereof.
[0034] The locking operation is carried out by first threading the auxiliary cables C 1 and C 2 under the bridge portion 230 b ( FIG. 6 a ) and rotating the yoke member 230 back, wherein the slot 238 overlies the tip 256 . The tip 256 is then pushed up and rotated by 90° as shown in FIG. 6 c. This enables the insertion of the tip 256 along with the projections 240 , 240 ′ into the slot S of the computer wall 210 a.
[0035] Then, the tip 256 is pushed further (if necessary) and again rotated by 90° so that it becomes positioned perpendicularly to, and behind the slot S thus completeing the engagement of the locking device to the computer wall 210 a ( FIG. 6 f ).
[0036] The lock casing 216 as a whole as well as the yoke member 230 , are prevented from being turned one way or the other because of the projections 240 and 240 ′ which are nested within the designated slot S.
[0037] It has been thus established that the present invention offers a neat and low-cost solution to the need of protecting, incidentally to the protection of the computer (or other valuable devices) against theft, all kinds of additional items which are actually connected to the computer by electric cables. The invention lends itself to be easily tailored to fit most kinds and models of presently used cable locks, or as a stand-alone device.
[0038] Those skilled in the art, that the invention has been described hereabove with reference to certain examples and specific embodiments. However, these are not the only examples and embodiments in which the invention may be practiced. Indeed, various modifications may be made to the above-described examples and embodiments without departing from the intended spirit and scope of the present invention, and it is intended that all such modifications be included within the scope of the following claims. | An improved locking device especially for portable computers of the type comprising a lock casing connectable on the one hand to an immovable object by a safety cable, and on the other hand to the protected object intermediate a designated slot formed in a side wall of the computer. The improvement consists of a yoke-member which comprises a first portion configured to be in the engaged state, entrapped between the lock casing and the side wall. A second portion of the yoke member bridges over the lock casing, forming an enclosed hollow thereunder through which electric cables of auxiliary equipment such as mouse and keyboard are passed. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to micropumps and in particular to their use in an integrated circuit cooling device.
[0003] 2. Discussion of the Related Art
[0004] A known cooling device is a metal heat sink placed against a surface of an integrated circuit chip. The carrying off of the heat from a “hot” area of the circuit to the heat sink is performed through a portion of the circuit generally exhibiting poor thermal conductivity.
[0005] As a complement to such a heat sink, or if no other cooling device is present, the integrated circuit is placed in an enclosure comprising a blower generating a permanent air current around the circuit.
[0006] These two cooling devices, associated or not, may not provide sufficient cooling down of a circuit having a high active density of components.
[0007] An object of the present invention is to provide a cooling device capable of maintaining at an acceptable level the temperature of an integrated circuit comprising a large number of active components.
[0008] A more general object of the present invention is to provide a micropump.
[0009] To achieve this, the present invention provides a pump comprising: a cavity formed in an insulating substrate, the upper portion of the substrate located in the vicinity of the cavity forming a border, a conductive layer covering the inside of the cavity all the way to the border and possibly covering the border, a flexible membrane, formed of a conductive material, placed above the cavity and bearing against the border, a dielectric layer covering the conductive layer or the membrane to insulate the portions of the conductive layer and of the membrane which are close to each other, at least one ventilating duct formed in the insulating substrate which emerges into the cavity through an opening of the conductive layer, and terminals of application of a voltage between the conductive layer and the membrane.
[0010] According to an embodiment of the above-mentioned pump, said cavity has substantially the shape of a cup such that the interval between the conductive layer and the membrane progressively increases from the border to the bottom of the cavity.
[0011] According to an embodiment of the above-mentioned pump, the membrane is in an idle state when no voltage is applied between said terminals, the application of a voltage deforming the membrane by drawing it closer to the conductive layer, the removal of the voltage bringing the membrane back to its idle state.
[0012] According to an embodiment of the above-mentioned pump, the pump comprises a single ventilating duct emerging substantially at the bottom of the cavity.
[0013] According to an embodiment of the above-mentioned pump, the pump comprises two ventilating ducts, one emerging substantially at the bottom of the cavity, the other one emerging close to the border.
[0014] According to an embodiment of the above-mentioned pump, the pump is connected to an assembly of ventilating ducts formed in the semiconductor substrate of the integrated circuit.
[0015] The present invention also provides a method for forming a pump in an integrated circuit, comprising the steps of: forming a cavity in an insulating substrate, the upper portion of the substrate located in the vicinity of the cavity forming a border; covering the inside of the cavity all the way to the border and possibly the border with a first conductive layer; forming an opening of the conductive layer emerging into a ventilating duct previously formed in the insulating substrate; filling the cavity with a sacrificial portion; covering the sacrificial portion and the portion of the first conductive layer placed above the border with a first insulating layer and with a second insulating layer; forming a small opening in the second conductive layer and in the first insulating layer; removing the sacrificial portion; and covering the second conductive layer with a second insulating layer to close back the opening.
[0016] According to an embodiment of the present invention, the step of forming a cavity in an insulating substrate comprises the steps of: forming insulating pads on a first insulating layer; covering the first insulating layer and the insulating pads with a second insulating layer; and performing a chem.-mech. polishing of the second insulating layer to expose the insulating pads, the etch method of the polishing being such that it etches the second insulating layer more than the insulating pads, the insulating pads forming said border.
[0017] The present invention also provides a method for actuating a pump such as described hereabove, in which a voltage is applied at regular or irregular intervals between said terminals.
[0018] The foregoing object, features, and advantages of the present invention will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWING
[0019] FIGS. 1 and 2 are cross-section views of a pump according to the present invention in two operating states;
[0020] FIG. 3 is a top view of the pump shown in FIGS. 1 and 2 ;
[0021] FIGS. 4 and 5 are cross-section views of another example of a pump according to the present invention in two operating states;
[0022] FIGS. 6A to 6 I are cross-section views of structures obtained in successive steps of a method for forming a pump according to the present invention; and
[0023] FIG. 7 is a cross-section view of an example of an integrated circuit comprising a pump according to the present invention.
DETAILED DESCRIPTION
[0024] As usual in the representation of integrated circuits, the various drawings are not to scale.
[0025] 1. Pump
[0026] FIGS. 1 and 2 are cross-section views of a pump according to the present invention respectively in an idle state and in an activation state. FIG. 3 is a top view of the pump shown in FIGS. 1 and 2 . The pump is formed above an insulating substrate 1 and more specifically in an upper cavity 2 of substrate 1 . Cavity 2 has in this example the shape of a cup. The upper portion of substrate 1 located in the vicinity of the cavity forms a border, having in this example a circular shape such as visible in FIG. 3 . The inside and the border of cavity 2 are covered with a conductive layer 3 , for example, made of copper or of aluminum. An opening O 1 of conductive layer 3 is formed substantially at the bottom of cavity 2 above a ventilating duct 4 formed in substrate 1 . Ventilating duct 4 emerges outside of the substrate. A flexible membrane 6 , formed of a conductive material, is placed above cavity 2 and bears against the border of cavity 2 above conductive layer 3 . Membrane 6 and conductive layer 3 are insulated from each other by an insulating layer 7 covering in this example the lower surface of flexible membrane 6 . Conductive layer 3 and flexible membrane 6 are connected to two terminals between which a control circuit V applies a voltage when ordered to do so.
[0027] In the idle state, when control circuit V applies no voltage, membrane 6 and insulating layer 7 are substantially horizontal, as shown in FIG. 1 . In the activation state, when control circuit V applies a voltage, membrane 6 deforms by coming closer to conductive layer 3 , as shown in FIG. 2 . When membrane 6 deforms, the volume of the air pocket located between membrane 6 and conductive layer 3 decreases, which results in chasing the air towards ventilating duct 4 . When control circuit V stops applying a voltage, membrane 6 separates from conductive layer 3 to return to its idle state horizontal position. The volume of the air pocket then progressively increases, which results in letting air into ventilating duct 4 . By successively repeating the operations of deformation and release of membrane 6 , it is thus possible to alternately let in “fresh” air and let out “hot” air.
[0028] According to an alternative embodiment of the above-described pump, insulating layer 7 covers conductive layer 3 . Opening O 1 is then formed through insulating layer 7 and conductive layer 3 .
[0029] FIGS. 4 and 5 are cross-section views of another example of a pump according to the present invention respectively in an idle state and in an activation state. The pump has a structure substantially identical to that of the pump shown in FIGS. 1 to 3 . The pump further comprises a second ventilating duct 10 connected to a second opening of the substrate and emerging into a second opening O 2 of conductive layer 3 formed close to the border of cup-shaped cavity 2 .
[0030] When control circuit V applies a voltage, membrane 6 progressively deforms and by coming closer to conductive layer 3 , it covers opening O 2 . Then, the increasing deformation of the membrane reduces the air pocket volume and chases hot air out of ventilating duct 4 . When control circuit V stops applying a voltage, membrane 6 progressively relaxes to return to its idle state. As long as membrane 6 covers opening O 2 , air enters the cavity through ventilating duct 4 . As soon as opening O 2 is uncovered, air enters cavity 2 through the two ventilating ducts 4 and 10 .
[0031] In the case where the size of opening O 2 is much larger than that of opening O 1 , the air volume entering through opening O 2 is much larger than that entering through opening O 1 . Thus, upon relaxation of membrane 6 , it is possible to fill cavity 2 with air principally coming from ventilating duct 10 . Accordingly, the coming in of “fresh” air into cavity 2 mainly occurs through ventilating duct 10 and the coming out of “hot” air mainly occurs through ventilating duct 4 .
[0032] As an example, the sizes of the various pump elements are the following:
diameter of the cup-shaped cavity: from 100 to 1000 μm maximum depth of the cavity (at the center): 15 μm diameter of ventilating duct 4 (opening O 1 ): from 1 to 10 μm diameter of ventilating duct 10 : from 1 to 10 μm thickness of conductive layer 3 : from 100 nm to 2 μm thickness of membrane 6 : 2 μm
[0039] When the control circuit applies a voltage between layer 3 and membrane 6 , the deformation of membrane 6 is progressive. The portions of layer 3 and of membrane 6 located in the vicinity of the border of cavity 2 are close to each other and a small voltage enables drawing them closer. Once these first portions have been drawn closer to each other, the portions of layer 3 and of membrane 6 located right next to them are then close to each other and a small voltage enables drawing them closer, and so on. The maximum deformation is that for which the “mechanical” membrane restoring force becomes equal to the electrostatic force created between layer 3 and membrane 6 by application of a voltage by control circuit V.
[0040] An advantage of the above-described pumps is that they can be activated with a small voltage.
[0041] The above-described pumps have a cup shape, which has the above-mentioned advantage. However, other cavity shapes may be imagined in which the conductive layer placed inside of the cavity and the flexible membrane placed above the cavity are not necessarily in contact on the cavity border.
[0042] 2. Pump Manufacturing Method
[0043] A pump according to the present invention can be formed according to the method described hereafter.
[0044] In an initial step, illustrated in FIG. 6A , a cup-shaped cavity 20 is formed in an insulating substrate 21 . The upper part of the substrate located close to the cavity forms a border. The cavity will preferably be “cup”-shaped so that the cavity depth progressively increases from the border to the bottom of the cavity.
[0045] The cup shape can be obtained according to the following method. Insulating pads 23 and 24 are formed on an insulating layer 22 . Insulating layer 22 and possibly pads 23 and 24 are then covered with a second insulating layer 25 . A chem.-mech. polishing of second insulating layer 25 is then performed to expose insulating pads 23 and 24 . The etch method implemented in the polishing is selected to that it “etches” insulating layer 25 more than pads 23 and 24 . When pads 23 and 24 are relatively spaced apart, a recess forms in insulating layer 25 between pads 23 and 24 . This phenomenon, known as “dishing”, is generally not desirable since it results in the forming of non-planar surfaces. However, advantage is taken of this phenomenon in the method of the present invention to form a cup-shaped cavity.
[0046] At the next step, illustrated in FIG. 6B , the inside and the border of cavity 20 are covered with a conductive layer 30 , for example, made of aluminum.
[0047] At the next step, illustrated in FIG. 6C , conductive layer 30 is etched to form an opening O 3 at the bottom of cavity 20 above a ventilating duct 31 previously formed in substrate 21 .
[0048] At the next step, illustrated in FIG. 6D , cavity 20 is filled with a sacrificial portion 32 . Sacrificial portion 32 does not cover the border of cavity 20 . A method of sacrificial layer deposition which conforms as little as possible may be used to avoid filling ventilating duct 31 . An etch or a chem.-mech. polishing of the sacrificial layer is then performed to remove the portions covering the border of cavity 20 .
[0049] At the next step, illustrated in FIG. 6E , an insulating layer 33 is formed above sacrificial portion 32 and above the portions of conductive layer 30 located on the border of cavity 20 .
[0050] At the next step, illustrated in FIG. 6F , insulating layer 33 is covered with a conductive layer 34 .
[0051] At the next step, illustrated in FIG. 6G , a small opening O 4 is formed in conductive layer 34 and in insulating layer 33 to reach underlying sacrificial portion 32 .
[0052] At the next step, illustrated in FIG. 6H , sacrificial portion 32 is removed through opening O 4 , for example, by etching.
[0053] At the next step, illustrated in FIG. 61 , conductive layer 34 is covered with a thin insulating layer 35 according to a method which is as little conformal as possible so that the deposited insulating layer penetrates as little as possible through opening O 4 .
[0054] 3. Pump Placed in an Integrated Circuit
[0055] A pump according to the present invention may be used to have air or another fluid flow through an assembly of ventilating ducts formed in an integrated circuit to cool it down. An example of ventilating ducts and a method for forming such ventilating ducts are described in “Micromachining of Buried Micro Channels in Silicon”, JOURNAL OF MICROELECTROMECHANICAL SYSTEMS, Vol. 9, N°1, March 2000, which is incorporated herein by reference.
[0056] FIG. 7 is a cross-section view of an example of an integrated circuit comprising a pump according to the present invention. Components 40 , such as MOS transistors, are formed at the surface of a semiconductor substrate 41 . A network of ventilating ducts 42 is provided in semiconductor substrate 41 . A network of metal interconnects 43 is placed above components 40 and substrate 41 . Interconnect network 43 comprises in this example five metallization levels on which are formed various conductive lines. Conductive vias enable connecting conductive lines placed on two adjacent levels. A micropump according to the present invention is placed in this example above interconnect network 43 and more specifically in a cup-shaped cavity 45 formed in the upper insulating layer of the last metallization level. A conductive layer 46 covers the inside and the border of cavity 45 . A conductive layer 47 , covered at its lower surface with an insulating layer 48 , is placed above cavity 45 by bearing against the border. A vertical opening, corresponding to a duct 49 , is formed through interconnect network 43 . Duct 49 emerges on the one hand into cavity 45 of the pump through an opening of conductive layer 46 and on the other hand into ventilating duct 42 provided in semiconductor substrate 41 . The pump is placed under a protection “bell” formed of an insulating portion 54 substantially having the shape of a hemisphere laid on interconnect network 43 .
[0057] On one of the sides of cavity 45 , insulating layer 48 extends to partially cover the upper insulating layer of interconnect network 43 . Conductive layer 47 continues above the extension of insulating layer 48 to cover a portion of the upper insulating layer in which is placed a conductive via 50 connected to a conductive line 51 of interconnect network 43 . Conductive layer 46 is connected to a conductive line 52 of the interconnect network via a conductive via 53 placed under conductive layer 46 . Conductive lines 51 and 52 enable connecting conductive layers 46 and 47 to a control circuit V formed in the integrated circuit substrate.
[0058] Such an integrated circuit may comprise a temperature sensor. The control circuit may activate more or less rapidly the pump according to the measured temperature.
[0059] Other embodiments of an integrated circuit comprising a pump according to the present invention may be imagined. The pump may for example be placed right above semiconductor substrate 41 under interconnect network 43 .
[0060] Of course, the present invention is likely to have various alterations, modifications, and improvements which will readily occur to those skilled in the art. In particular, those skilled in the art may imagine other methods for manufacturing a pump according to the present invention. Further, the number and the location of the openings formed in the lower conductive layer of the pump will be determined according to the ventilating ducts provided in the integrated circuit.
[0061] Having thus described at least one illustrative embodiment of the invention, various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be within the scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto. | A pump having: a cavity formed inside an insulating substrate, the upper part of the substrate being situated near the cavity having an edge; a conductive layer covering the inside of the cavity up to the edge and optionally covering the edge itself; a flexible membrane made of a conductive material placed above the cavity and resting against the edge; a dielectric layer covering the conductive layer or the membrane whereby insulating the portions of the conductive layer and of the membrane that are near one another; at least one aeration line formed in the insulating substrate that opens into the cavity via an opening in the conductive layer, and; terminals for applying a voltage between the conductive layer and the membrane. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/256,612, filed on Oct. 30, 2009. The disclosure of the above application is incorporated herein by reference in its entirety.
FIELD
[0002] The present disclosure relates to diagnostic systems and methods for engine control systems, and more particularly to diagnostic systems and methods for throttle body assemblies.
BACKGROUND
[0003] The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
[0004] Vehicles typically include a throttle assembly that includes a throttle blade that is adjusted by a motor. A throttle position sensor senses a position of the throttle blade. In many vehicles, the throttle position of the throttle blade changes in a one-to-one relationship with changes in position of an accelerator pedal.
[0005] More recently, some vehicles employ a different control strategy in which the accelerator pedal position to throttle position mapping is not a one-to-one relationship. For example only, torque-based control systems may not have the one-to-one relationship.
[0006] In these types of systems, it is unlikely that every operating point of the throttle body may be encountered during use. If a problem with the throttle body occurs at one of the unlikely operating points, a vehicle diagnostic system and/or technician may be unable to accurately diagnose faults in the throttle body assembly.
SUMMARY
[0007] A throttle diagnostic system includes a diagnostic device comprising a throttle sweep diagnostic module that generates N throttle position commands at a first predetermined interval. The N throttle position commands differ by a predetermined interval. N is an integer greater than or equal to 25. A vehicle control system comprises a throttle body assembly that receives the N throttle position commands. A throttle diagnostic module performs diagnostics on the throttle body assembly at a second predetermined interval that is less than the first predetermined interval.
[0008] In other features, the N throttle position commands are equally spaced between a minimum throttle position and a maximum throttle position. The minimum throttle position is 0% and the maximum throttle position is 100%. The predetermined interval is 1%. The first predetermined period is between 1.25 and 1.5 times the second predetermined period. The first predetermined period is between approximately 250 and 300 ms and the second predetermined period is approximately 200 ms.
[0009] A throttle diagnostic system comprises a throttle sweep diagnostic module that sends N throttle position commands at a first predetermined interval to a throttle body assembly. The N throttle position commands differ by a predetermined interval. N is an integer greater than or equal to 25. A throttle diagnostic module performs diagnostics on the throttle body assembly at a second predetermined interval that is less than the first predetermined interval.
[0010] In other features, the N throttle position commands are equally spaced between a minimum throttle position and a maximum throttle position. The minimum throttle position is 0% and the maximum throttle position is 100%. The predetermined interval is 1%. The first predetermined period is between 1.25 and 1.5 times the second predetermined period. The first predetermined period is between approximately 250 and 300 ms and the second predetermined period is approximately 200 ms.
[0011] In still other features, the systems and methods described above are implemented by a computer program executed by one or more processors. The computer program can reside on a tangible computer readable medium such as but not limited to memory, nonvolatile data storage, and/or other suitable tangible storage mediums.
[0012] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0014] FIG. 1 is a functional block diagram of an exemplary throttle body sweep diagnostic system according to the present disclosure;
[0015] FIG. 2 is a functional block diagram of another exemplary throttle body sweep diagnostic system according to the present disclosure; and
[0016] FIG. 3 illustrates steps of a method for performing a throttle body sweep diagnostic system according to the present disclosure.
DETAILED DESCRIPTION
[0017] The following description is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical or. It should be understood that steps within a method may be executed in different order without altering the principles of the present disclosure.
[0018] As used herein, the term module refers to an Application Specific Integrated Circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.
[0019] Conventional throttle diagnostic tests are not typically repeatable. Some conventional throttle diagnostic tests require manual operation of the accelerator pedal. Other tests provide manual selection of course throttle increments such as 10% increments. The diagnostic system may only detect a fault if the throttle position is maintained during a diagnostic window such as 200 ms. These manual types of tests often fail to properly diagnose the fault.
[0020] A throttle sweep diagnostic system and method according to the present disclosure performs a throttle diagnostic sweep test. A vehicle control system or a diagnostic device performs the throttle diagnostic sweep test. The throttle diagnostic sweep test sweeps the throttle position from a minimum position to a maximum position (or vice versa) via predetermined throttle increments at predetermined intervals.
[0021] The throttle diagnostic sweep test leaves the throttle position at a new setting for a first predetermined period that is longer than a second predetermined period required by an on-board diagnostic system of the vehicle control system to diagnose a fault. The predetermined throttle increments are selected to be sufficiently small to identify throttle motor faults such as faults in a commutator of a motor (used to position the throttle blade) or sensor tracks of a throttle position sensor (used to sense a position of the throttle blade).
[0022] Referring now to FIG. 1 , a vehicle diagnostic system 10 includes a diagnostic device 20 and a vehicle control system 24 . The diagnostic device 20 includes an interface 26 that communicates with an interface 28 of the vehicle control system 24 . For example only, the interfaces 26 and 28 can be On-Board Diagnostic (OBD)-complaint ports, assembly line data links (ALDLs), universal serial bus (USB) interfaces, and/or any other suitable interfaces.
[0023] The diagnostic device 20 further includes a processing module 34 that provides data and control processing. The diagnostic device 20 further includes a throttle sweep diagnostic module 36 that sends throttle position commands at predetermined intervals and checks for diagnostic codes being set as will be described further below. The diagnostic device 20 further includes a display 38 and an input device 42 such as a keyboard, touch screen and/or other suitable input device.
[0024] The vehicle control system 24 further includes a control module 48 that includes a throttle diagnostic module 50 . The control module 48 may be implemented by the engine control module or any other suitable vehicle control module. The control module 48 communicates with a throttle body assembly 52 that includes a throttle blade motor 54 and a throttle position sensor 56 . The commanded throttle position is sent to the throttle blade motor 54 . The throttle position sensor 56 senses a position of a throttle blade (not shown).
[0025] The throttle diagnostic module 50 compares a commanded throttle position sent to the throttle blade motor 54 with an actual throttle position sensed by the throttle position sensor 56 . If the difference between the commanded throttle position and the actual throttle position is outside of a predetermined range, takes too long to reach the correct position, fails to settle or fails to meet any other calibration parameter, the throttle diagnostic module 50 triggers a fault.
[0026] Typically, the throttle diagnostic module 50 performs a diagnostic routine once every predetermined period. In other words, the throttle diagnostic module 50 determines whether or not the throttle body assembly is operational or not operational once every predetermined period or within a predetermined period after a new throttle position is commanded. Each of the commanded throttle positions is set and maintained for a sufficient amount of time to allow the throttle diagnostic module to determine if a fault has occurred.
[0027] Referring now to FIG. 2 , an alternate implementation of the vehicle control system 60 is shown. In FIG. 1 , the commanded throttle positions are sent to the vehicle control system 24 from an external diagnostic device. In the implementation in FIG. 2 , the throttle sweep diagnostic module 68 is integrated with a throttle diagnostic module 66 , which may form part of the control module 64 or any other vehicle control module. The control module 64 may be an engine control module.
[0028] The throttle sweep diagnostic module 68 operates in a similar manner as described above in conjunction with FIG. 1 . However, the vehicle control system 60 is able to initiate the throttle sweep test without receiving throttle commands from the external diagnostic device such as the diagnostic device in FIG. 1 . In some implementations, the diagnostic device may still be used to trigger the test.
[0029] Referring now to FIG. 3 , the method 100 begins at 102 . At 104 , the method determines whether or not the vehicle has (or had) an error code in a predetermined set of error codes at 102 . For example, the predetermined set of error codes may include one or more of the following OBD codes: P 1516 , P 2101 , P 2119 , P 2135 , P 0122 , P 0123 , P 0222 and P 0223 .
[0030] If 102 is true, the method determines whether or not there are any active error codes at 104 . If 104 is true, the error codes are reset at 108 . If the error code was set due to faulty vehicle wiring, the error code will return immediately. Otherwise if the vehicle wiring is not faulty, the code will not return until the throttle sweep test is completed. Thus, both the vehicle wiring and other components are tested. In some implementations, a timer may be added to allow at least one diagnostic period to elapse. After the period is up, control may be used to detect the triggering of the fault before the sweep test is run and a wiring fault may be generated identifying the vehicle wiring as the source of the fault.
[0031] When 104 is false, the method continues at 112 where the method determines whether a throttle sweep test has been selected via the diagnostic device or by the vehicle control system. If 112 is false, the method ends.
[0032] If 112 is true, the throttle position is set to a first throttle position at 114 . At 115 , the method waits a first predetermined period. The first predetermined period may be greater than a second predetermined period that is equal to a diagnostic response time of the vehicle control system.
[0033] At 116 , the method determines whether a diagnostic code has been set. For example only, the diagnostic codes may be OBD codes such as P 2101 or P 1516 . If 116 is true, the method displays a first message on the display 38 of the diagnostic device at 118 and the method ends. For example, the first message may be a message instructing a technician to change the throttle body assembly, a fault code set on the control module of the vehicle or any other indicator.
[0034] If 116 is false, control increments (or decrements if starting from 100%) the throttle position by a predetermined amount. At 122 , the method waits the first predetermined period. At 126 , control determines whether the throttle blade is at a maximum (or minimum if starting from 100%) throttle position. If 126 is false, control returns to step 116 . If 126 is true, control displays a second message on the diagnostic device at 128 . The second diagnostic message may indicate that the throttle body sweep diagnostic test was passed and the method ends.
[0035] For example only, the throttle diagnostic sweep test sweeps the throttle from 0% to 100% at 1-4% intervals. The first predetermined period may be between 1.25 and 1.5 times the second predetermined period. For example only, each interval is performed every 250 ms to 300 ms for a total sweep time of less than 25 to 30 seconds. In this example, the on-board diagnostic system diagnoses faults within 200 ms. If there are faults on the commutator of the motor or problems with the throttle position sensor, a resolution of 1-4% is fine enough to catch this type of problem. Therefore, the test includes at least 25 intervals. The test may be run with the engine off and the ignition switch on.
[0036] If the diagnostic device is used, the test can be run without intrusion into a wire harness or throttle body of the vehicle. The test is repeatable, which allows further investigation into failed parts by a supplier of the throttle body assembly. The test uses standard tools and does not require a special adapter harness, a custom power supply or a signal generator.
[0037] The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification, and the following claims. | A throttle diagnostic system comprises a diagnostic device comprising a throttle sweep diagnostic module that generates N throttle position commands at a first predetermined interval, wherein the N throttle position commands differ by a predetermined interval. A vehicle control system comprises a throttle body assembly that receive the N throttle position commands and a throttle diagnostic module that performs diagnostics on the throttle body assembly at a second predetermined interval that is less than the first predetermined interval. | 6 |
A principal object of this invention is to provide a more interesting and more challenging game of chess by providing a realistically three dimensional game board apparatus.
It is a further object to provide a three dimensional chess board apparatus that can be played from back to front or from side to side.
It is a further object to provide an apparatus that can be played from a bottom level to a high level at the center of the game apparatus or, by inverting the apparatus, the game can be played from a high level to a low level at the center.
In the game of chess, the chess pieces represent two sets of chess men, white and black, which are opposed in battle alignment. This battle alignment is more realistic if played on different levels, representing embankments. To accomplish this purpose, the chess game apparatus is arranged with its parallel rows of alternate black and white squares so that each row from the two center highest rows is lowered from the next preceeding row by a uniform distance or when the game apparatus is inverted each row from the center lowest rows are raised a uniform distance.
The chess game is much more realistic because the different levels of approach is more like the attack and conquest of the opposing forces in a real life situation where the action takes place on hill and dale, a three dimensional landscape. The lowest levels of the game apparatus could simulate a watery moat or a valley while the upper rows can simulate mountains from which the attack is made.
The number of squares are increased from the standard 64 to 80 by increasing the number of squares in a row to ten squares. This enables the use of the game apparatus for playing from side to side in addition to from front to back.
It is a further object to simulate real life combat into the chess game by using the natural colors for the squares as green and brown and to as closely as possible make each of the chess pieces simulate their actual form.
For a fuller understanding of the nature and objects of this invention reference should be had to the following detailed description taken in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a perspective view illustrating the chess game apparatus from low rows to high rows;
FIG. 2 is a perspective view of the chess game apparatus, as inverted, from high rows to low rows;
FIG. 3 is a side elevational cross-sectional view of FIG. 1 taken along line 3--3; and
FIG. 4 is a side elevation cross-sectional view of FIG. 2 taken along line 4--4.
DETAILED DESCRIPTION
Referring to the drawings wherein like numerals designate like parts, and referring to FIGS. 1 and 2, there is shown a chess apparatus comprising a three dimensional arrangement of black and white squares wherein the play area is supported by two 24''×7'' boards 20 shaped as illustrated with cross boards 21, and rows of squares 22 constructed as to represent a flight of steps going from down to up, as in FIG. 1 and FIG. 3, or going from up to down as shown in FIG. 2 and FIG. 4. FIGS. 3 and 4 show side elevational views of members 25 and 26.
Though the number of squares 23 can be 8 in a row and 8 rows, a total of 64 squares, which is conventional, it is preferred to increase each row to 10 squares, yielding a total of 80 squares. The increase in squares is essential if the chess apparatus is to be used from side to side as well as front to back. This game apparatus can be set up for playing in four different ways. Two ways have been described. The other two ways involve inverting the game apparatus as in FIG. 2 which also can be played from side to side as well as from front to back.
During use of the apparatus, the games of checkers or chess are played in the traditional manner except the plays or moves are performed in a vertical plane as well as a horizontal plane. This tends to make the game more interesting and challenging. The game of chess was originally a copy of actual battle scenes of roughened terrain, including valleys, hills, and moats. This game apparatus is therefore constructed to simulate this three dimensional field. As a further simulation other contrasting colors may be used instead of black and white. For instance, brown for ground and green for herbage. The frame may be also colored in a naturally occurring shade. The number of players could be increased to four because all four sides can be in play. Each player moves when his portion of the play area is involved. A more realistic setting can be provided by additionally modifying the shape of each chess piece to make them simulate actual warriors, people, and castles.
In order to provide a storing place for the checkers and chess pieces, a drawer on sliding tracks can be provided at the front and back members so that the checkers can be stored separately from the chess pieces.
The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof but it is recognized that various modifications are possible within the scope of the invention claimed. | A game apparatus for checkers and chess which is three dimensional to provide a simulated perspective of a combat zone by raising or lowering each successive row of squares, a uniform distance from front and back to the center of the apparatus. | 0 |
FIELD OF THE INVENTION
This invention relates to patient ventilator systems in which breathing gas is circulated through a carbon dioxide absorber canister, and more particularly, to an improved carbon dioxide absorber canister having an integral moisture sump.
BACKGROUND OF THE INVENTION
In ventilator systems designed to provide respiratory gases to patients, condensation of water vapor commonly occurs in breathing circuit components due to the high humidity of patients' expired gases. Breathing circuits of the re-circulatory type include a carbon dioxide absorbing canister. Condensate is especially troublesome in carbon dioxide absorbing canisters and associated tubing and valves and may interfere with proper operation of the canisters and breathing circuit. When a patient requires prolonged use of a ventilator system, substantial condensate can accumulate, requiring medical personnel attending the patient to periodically rid the ventilator system of the excessive moisture.
Prior art ventilator systems have utilized various sumps to trap and remove condensate. The carbon dioxide absorbing canister itself has often been relied on as a common sump although the canister's primary function is removing carbon dioxide from the patient's expired breathing gases.
However, there exist areas in the breathing circuit that are difficult to drain to the carbon dioxide absorber canister. For example, the canister inlet structure, located upstream of the canister itself, including the expiratory check valve of the breathing system, is inherently difficult to maintain free of excessive condensate. In prior systems, the periodic actuation of a valve by a patient attendee was necessary for removal of condensate in this area.
Alternatively, separate stand-alone sumps have been employed specifically to drain the moisture from problematic areas. These sumps allowed the patient's attendees to view the collected moisture through a window or a transparent container so that the attendee could empty the collected moisture before the sump overflowed into the breathing circuit.
In practice, both the valve actuation mechanisms and the stand alone sump arrangements require extensive vigilance on the part of the patient's attendees. This demand on the attendees only adds to the already numerous ventilator servicing requirements which include removing and replacing spent carbon dioxide absorbing materials from the canister, ensuring proper composition of ventilator gases, maintaining desired gas volumes and pressures in the breathing circuit, and maintaining optimum humidity in inspiratory breathing gases. These varied tasks create multiple opportunities for operating errors to occur.
Therefore, an approach that avoids the above-described condensate-related problems and reduces condensate buildup problems in hard to drain breathing circuit areas, while simultaneously lowering the demands on the patient attendees, is highly desirable.
SUMMARY OF THE INVENTION
This invention is a carbon dioxide absorber canister with an integral moisture sump. The moisture sump collects condensate from areas of a breathing circuit that are difficult to drain to a common sump, such as the carbon dioxide absorber canister itself. The moisture sump found in the present invention may be integrally formed into the structure of the carbon dioxide absorber canister, the canister including a hollow container adapted to contain a carbon dioxide absorbing material.
The moisture sump includes a reservoir chamber for accepting collected condensate. The reservoir chamber may be arcuately-shaped with an upwardly facing entrance formed by surrounding walls. The entrance to the reservoir chamber offers a sealing surface for pneumatically sealing with the breathing circuit. This pneumatic seal is arranged so that the seal is accomplished by attachment of the carbon dioxide absorber canister to the patient ventilator system and is broken when the canister is subsequently removed from the system.
The moisture sump is adapted to collect condensate from breathing circuit areas proximate the inlet and outlet ports of the canister. Such areas include the inlet structures and outlet structures located in the patient ventilator system, specifically, the expiratory check valve and the inspiratory check valve. As noted above, the expiratory check valve is known to be a particularly troublesome area from which to drain condensed moisture.
The moisture sump's reservoir chamber may have a volume sized to accommodate the maximum amount of condensate collected in a given time interval, such as the life expectancy of the carbon dioxide absorbing material contained within the hollow container of the canister. Therefore, the patient's attendees are not required to monitor the moisture buildup in the moisture sump independently of other tasks. Removal of the carbon dioxide absorber canister from the breathing circuit automatically ensures that the condensed moisture contained in the integral sump is also removed.
Further advantages of a carbon dioxide absorber canister with an integral moisture sump of the present invention will be evident from the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an overview of a ventilator breathing circuit showing elements of the circuit as distinct functional blocks.
FIG. 2 is a perspective view of a patient ventilator system including one embodiment of the carbon dioxide absorber canister with moisture sump according to the invention.
FIG. 3 is an exploded perspective view of the canister and associated valve structure depicted in FIG. 2 .
FIG. 4 is a cross-sectional view of the canister and associated valve structure shown in FIG. 2 taken generally along the line 4 — 4 of FIG. 2 .
FIG. 5 is an alternate embodiment of the carbon dioxide absorber canister and moisture sump shown in a cross-sectional view similar to FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
Like numerals are used to refer to like elements throughout the figures and the following description.
FIG. 1 is an overview of a patient ventilator breathing circuit 10 showing elements of the circuit as distinct functional blocks. Exhaled breathing gases initially travel from the patient through a flow sensor 12 . Flow sensor 12 provides output information to a patient attendee regarding flow characteristics of the exhaled gases. Expired breathing gases then flow to an expiration valve structure 16 . In expiration valve structure 16 , moisture is separated from the expired breathing gases and drains into moisture well or condensate sump 14 . The breathing gases then pass through the expiratory check valve 17 contained in the structure 16 associated with a CO 2 absorber (canister) 18 . Mechanical ventilator, or manually operated flexible bag, 20 is connected to the flow path for the breathing gases downstream of the expiratory check valve 17 to drive the re-circulating breathing gases through CO 2 absorber 18 . Within CO 2 absorber 18 , CO 2 gas is removed by contact with a CO 2 removing material, such as soda lime.
In FIG. 1, the functional blocks representing condensate well 14 and carbon dioxide absorber 18 are interconnected to graphically represent the integral design of these components found in the present invention. Also, and as shown in diagrammatic form in FIG. 1, moisture (water) carried by the breathing gases is removed from the gases before the gases pass through the expiratory check valve 17 , thereby avoiding an excessive build up of moisture that could interfere with the operation of the valve 17 . Further, removing moisture from the breathing gases upstream of the expiratory check valve 17 is advantageous in limiting or precluding moisture from entering ventilator/bag 20 .
After the CO 2 content of the expiratory gas is reduced in canister 18 , the expiratory gas exits CO 2 absorber 18 and fresh anesthesia gases, block 22 , are added if necessary. The gases flow through an inspiratory check valve 23 located within an inspiratory valve structure 24 before being returned to the patient. Between the inspiratory check valve 24 and the patient, a pressure sensor 26 , oxygen sensor 28 , flow sensor 30 , and other apparatus may be present.
FIG. 2 depicts a patient ventilator apparatus 32 including a CO 2 absorber canister 18 with an integral moisture sump 14 according to the present invention. FIG. 3 shows an exploded perspective view of the apparatus of FIG. 2 . FIG. 4 shows a cross-sectional view of the canister 18 with sump 14 of FIGS. 2 and 3.
Referring to FIGS. 2 and 3, a patient ventilator apparatus 32 includes a flow sensor module 36 partially enclosing a ventilator. 20 , an expiratory valve structure 16 and an inspiratory valve structure 24 . Expiratory valve structure 16 includes an expiratory valve inlet 34 seen protruding from ventilator housing 36 in FIG. 2 . Expiratory valve inlet 34 communicates with the expiratory valve body 38 located within flow sensor module 36 . Expiratory valve body 38 communicates with an expiratory valve outlet 40 located on the underside of the ventilator apparatus 32 .
FIG. 4 illustrates that between inlet 34 and outlet 40 , expiratory valve body 38 contains valve disk 41 mounted on valve seat 43 to control the passage of gas through the valve body 38 . The expiratory valve structure 16 communicates with ventilator 20 through ventilator port 94 . Ventilator port 94 is located downstream of the point in expiratory valve body 38 , at which moisture is removed from the expiration gases. Condensed moisture reaching ventilator 20 is thus largely reduced.
As seen in FIGS. 2-4, expiratory valve body 38 includes an expiratory valve drain 42 adapted to collect and route condensed moisture away from the expiratory valve body 38 . Condensate in the breathing circuit enters expiratory valve body 38 through valve inlet 34 and, unable to follow the upwardly leading path of the breathing gases shown by arrow a in FIG. 4, will drain to a lower portion 78 of the expiratory valve body 38 . Condensate collected at the lower portion 78 then enters valve drain 42 and travels downward to reservoir chamber 80 of moisture sump 14 . Reservoir chamber 80 is formed by sump wall 82 which extends from an upper entrance 84 downward to transition into a bottom 86 . Lower portion 48 of drain tube 42 forms a pneumatic seal with reservoir chamber 80 through O-ring 46 .
The preferred embodiment of the invention utilizes an arcuately-shaped reservoir chamber 80 formed by sump wall 82 which is integral with container wall 88 as shown in FIGS. 2-4. However, reservoir chamber 80 and container chamber 90 are physically isolated from each other, as shown in FIG. 4 . Container body 44 and sump 14 are preferably molded as a single unit. Suitable materials may include polysulfones with polyphenyl sulfone being preferred since these materials can withstand autoclaving. Polypropylene would also be a suitable material for canister construction.
Expiratory valve outlet 40 forms a pneumatic seal with a canister inlet port 52 located on a top 54 of hollow container body 44 . Expiratory gases exiting valve outlet 40 are conveyed in the direction of arrow b to container body 44 where they interact with a CO 2 absorbing material contained therein. The CO 2 absorbing material may be any material suitable for removing CO 2 from breathing gas. Soda lime is the preferred material.
As shown in FIG. 4, the breathing gases exit hollow container body 44 in the direction of arrow c through a canister outlet port 56 located on top 54 of container body 44 . An inspiratory valve inlet 58 forms a pneumatic seal with the canister outlet port 56 and carries the breathing gases upward to the inspiratory valve body 60 (arrow d). Inspiratory valve body 60 is equipped with a gas flow controlling valve disk 61 and seat 63 , and an inspiratory valve outlet 62 which is in communication with subsequent elements of the breathing circuit. A fresh breathing gas port 64 communicates with inspiratory valve body 60 so that fresh breathing gases may be introduced into the breathing circuit if so desired by patient attendees.
Canister 18 with integral sump 14 is secured to the expiratory valve outlet 40 , expiratory valve moisture drain 42 , and inspiratory valve inlet 58 through latches 66 located on top 54 of the hollow container body 44 which opposingly engage fixed latch receiving members 68 and movable-type latch receiving members 70 . Movable type latch receiving members 70 are located on a latch actuator mechanism 72 which includes a latch actuator 74 . The latch actuator 74 may be operated by a patient attendee to disengage the movable members 70 from the latches 66 to break the pneumatic seals between valves 16 , 24 , drain 42 and the carbon dioxide absorber canister 18 and moisture sump 14 .
Following replacement of the CO 2 absorbing material and emptying of the moisture sump 14 , the canister 18 with sump 14 may be reinstalled via the latching mechanism 72 to reestablish the pneumatic seals and consequently direct the expiratory gases of the breathing circuit past the moisture sump 14 and through container body 44 .
As noted above, the container body 44 is adapted to contain an amount of CO 2 absorbing material, suitable for removing CO 2 from a given volume of breathing gases. The volume of the reservoir chamber 80 of sump 14 is appropriately sized to accommodate the maximum amount of condensate produced from the given volume. Therefore, a patient attendee need not be burdened with checking and removing/replacing a moisture sump separate from removing and replacing a CO 2 absorber canister.
The integrated moisture sump 14 acts as a trap for condensed moisture formed before expired gases reach canister 18 . The invention ensures that not only the expiratory valve 16 remains free of condensed moisture but that excessive moisture does not build up in the container chamber 90 of the canister 18 . This improvement allows for less erratic response of the expiratory valve 16 as well as increased life and efficiency of the CO 2 absorbing material.
FIG. 5 depicts an alternative embodiment of the invention. FIGS. 1-4 show a single sump 14 on canister 18 . In the embodiment shown in FIG. 5, a second moisture sump 92 provided on canister 18 to collect condensed moisture from an inspiratory valve drain (not shown) is alternately provided. The second moisture sump 92 shown in this embodiment resembles the first moisture sump 14 and appropriate modifications are made to canister 18 and valve structures 16 and 24 .
Various alternatives and embodiments are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention. | A moisture sump integrated into a carbon dioxide absorber canister provides a collection reservoir for condensate from a patient ventilator system when the carbon dioxide absorber canister is attached to the ventilator system. The volume of the moisture sump is appropriately sized so that the time interval required to collect a maximum amount of condensate interval is not more than the life expectancy of the carbon dioxide absorbing material contained within the canister. The moisture sump allows condensate management of difficult to drain areas such as the inlet to the expiratory check valve of a ventilator system. The removal of the carbon dioxide absorber canister by a patient attendee to replace the carbon dioxide absorbing material ensures that the condensate collected by the integral moisture sump is eliminated from the patient ventilator system. | 0 |
This is a division of application Ser. No. 29,420, filed Apr. 12, 1979, now U.S. Pat. No. 4,230,625.
BACKGROUND OF THE INVENTION
Chenodeoxycholic acid has exhibited valuable therapeutic activity, particularly as an agent for dissolution of cholesterol gallstones. This compound is currently obtained from cholic acid. An exemplary synthesis starting from cholic acid is described in U.S. Pat. No. 3,836,550. However, this process is of limited importance due to the circumstances which exist regarding the natural sources of cholic acid which is extracted from cow bile or with some additional processing from chicken bile. Calculations based on estimated demand for chenodeoxycholic acid assuming only one-third the potential patients utilize this drug indicate that such natural sources even if utilized to maximum potential could provide only a minor portion of such demand. Thus, an efficient synthesis from highly abundant starting materials is an important factor in determining whether chenodeoxycholic acid achieves its potential role in medicine.
Hydroxylation at the 7-position of compounds in the androstane and pregnane series is well known in the art. An early report by Kramli and Horvath, Nature, 4120, 619 (1948) indicated the 7-hydroxylation of cholesterol by incubation with Proactinomyces roseus was carried out but the actual configuration of the product was not determined. Well documented reports of 7-alpha-hydroxylation on the following substrates appear in the art:
deoxycorticosterone--Meystre et al., Helv. Chim. Acta 38, 381(1955).
progesterone and related compounds--U.S. Pat. No. 2,753,290, U.S. Pat. No. 2,836,608, McAleer et al., J. Org. Chem. 23, 958 (1958).
testosterones--U.S. Pat. No. 2,801,251, U.S. Pat. No. 2,960,436, Irmscher et al., Chemische Berichten 97, 3363 (1964).
A-nor steroids--U.S. Pat. No. 3,005,018 Laskin and Weisenborn, Bact. Proc. 26, A26 (1962).
17-alkyl androstanes and pregnenes--Singh et al., Can. J. of Microbiol. 13, 1271 (1967).
androstenedione--Abdul-Hajj. Lloydia 33(2), 278 (1970).
estradiols--Chem. Abstracts 86, 73006s (1977).
Botryodiplodia theobromae is known to be capable of 11-alpha-hydroxylating steroids (U.S. Pat. No. 3,047,470). Lasiodiplodia theobromae and Botryodiplodia theobromae are effective agents for the reduction of pyridine and of pyrimidine compounds. See for example Howe and Moore, J. Med. Chem. 14 (4), 287 (1971); British Pat. No. 1,183,850; and Howe et al., J. Med. Chem. 15, 1040 (1972). Lasiodiplodia theobromae has also been reported to oxidize mycophenolic acid. Jones et al., J. Chem. Soc. (C), 1725 (1970).
DESCRIPTION OF THE INVENTION
The present invention relates to an efficient synthesis of chenodeoxycholic acid having the structure below ##STR1## starting from 3-keto-bisnorcholenol (also named 22-hydroxy-23,24-bisnorchol-4-en-3-one) a compound of the formula: ##STR2## which is readily obtained by the microbiological degradation of the commercially available β-sitosterol by procedures well known to the art.
In the initial process step of the present invention 3-keto-bisnorcholenol is microbiologically hydroxylated in the 7-position to produce 7-alpha-hydroxy-3-ketobisnorcholenol (7α,22-dihydroxy-23,24-bisnorchol-4-en-3-one) of the formula: ##STR3##
Of the 152 cultures examined for 7-alpha hydroxylation, such cultures representing 92 species in 41 genera and including many reported capable of 7-alpha hydroxylation of the various substrate compounds enumerated above, it has now been unexpectedly found that only 9 very closely related cultures, Botryodiplodia theobromae IFO 6469, ATCC 28570, DSM 62-678, DSM 62-679; Botryosphaeria ribis ATCC 22802, B. berengeriana ATCC 12557, B. rhodina CBS 374.54, CBS 287.47 and CBS 306.58, are capable of carrying out the desired 7-alpha hydroxylation on this sterol substrate.
The microorganism may be used in the form of the culture broth, the mycelia or an enzyme extract thereof. The culture broth may be prepared by inoculating the organism into a suitable medium. The culture medium can contain carbon sources, nitrogen sources, inorganic salts and other nutrients suitable for the growth of the microorganisms. The carbon sources are, for example, glucose, sucrose, dextrin, mannose, starch, lactose, glycerol and the like, the nitrogen sources are e.g. nitrogen-containing organic substances, such as peptone, meat extract, yeast extract, corn steep liquor, casein and the like, or nitrogen-containing inorganic compounds, such as nitrates, inorganic ammonium salts and the like, and the inorganic salts such as phosphates or minerals such as sodium, potassium, magnesium, manganese, iron, copper and the like.
As the cultivation method employed in this process step of the invention there can be utilized submerged culture, shaking culture, stationary culture and the like. However, since aerobic conditions are required for organisms used in this invention, it is preferable to cultivate under conditions which promote aeration.
In addition it is possible to employ in the practice of the present invention a mycelium isolated from the culture broth of the microorganisms, or a crude enzyme extracted from the culture broth or the mycelium by a known method per se can be brought into contact with the substrate under suitable conditions. In the case when such a process embodiment is adopted the 7α-hydroxylation can be conveniently performed in an aqueous solution such as a buffer solution, a physiological salt solution or a fresh medium, or in water.
The substrate compound may be added in the form of an unpalpable powder or in the form of a solution dissolved in a hydrophilic solvent such as acetone, dimethylsulfoxide, methanol, ethanol, ethylene glycol, propylene glycol, dioxane and the like. Alternatively, a surfactant or a dispersing agent may be added to a water suspension of the substrate. Furthermore, the substrate can be prepared as a finely divided suspension by treatment with ultrasonic waves.
The fermentation procedure employs conventional techniques. Thus, the desired microorganism may be grown in Edamin broth (same as fermentation medium; see below) for a period of from 18 to 72 hours at a temperature in the range of about 15° to 35° C. Fermentation is initiated by inoculating a conventional fermentation medium with from 1to 10 wt % of the vegetative growth. The fermentation conditions can be the same as was utilized to grow the inoculum. After an incubation period of from 18 to 96 hours, the substrate bisnorcholenol is added either as a solution in, preferably absolute ethanol or as a sonically prepared solution in 0.1% Tween 80 (polyoxyethylene sorbitan monooleate). The fermentation may be carried out for up to 120 hours after addition of the substrate. A suitable fermentation medium is obtained by mixing the following or multiple thereof. Edamin (Sheffield Chemical Co.), an enzymatic digest of lactalbumin 20 grams, cornsteep liquor 3grams, dextrose 50 grams and distilled water to a final volume of 1 liter. The pH of the medium is adjusted to about 4 to 7, preferably about 5.0 prior to sterilization e.g. by autoclaving.
Isolation of the desired 7-alpha-hydroxy-3-keto-bisnorchlorenol product from the fermentation medium is readily accomplished using procedures well known in the art. Thus, the harvested whole culture broth can be extracted with a non-miscible organic solvent such as preferably ethyl acetate. The solvent soluble fractions may then be purified using gel chromatography such as for example with silica gel G-60, followed by crystallization.
It has further been found that a number of procedures can be employed to optimize the yield of desired product from the fermentation. Thus, for example, addition of a chelating agent such as 2,2'-dipyridyl in a final concentration ranging from 0.5×10 -4 M to 0.75×10 -3 M, addition with the substrate of either glucose or sucrose in a final concentration of about 5%, lowering the temperature of the incubation fermentation to about 24° C., after adding the substrate and by using a suspension of substrate at a concentration of 5% in 0.1% Tween 80. An even greater increase in yield is obtainable by the addition of adsorbants to the fermentation medium. For example yield improvement is obtained when polymeric resin absorbents such as Amberlite XAD7 (Rohm & Haas Co.), a polymer of the methyl ester of acrylic acid is added at a concentration 0.3-0.6 wt % to a fermentation medium where the substrate is present in a concentration of up to about 1 g/liter. Best yield improvement was obtained at about the 0.6 wt % concentration level for the adsorbent.
The 7-alpha-hydroxy-3-keto-bisnorcholenol produced by the above described fermentation procedure is then catalytically hydrogenated so as to produce (5β)-7α,22-dihydroxy-23,24-bisnorcholan-3-one of the formula- ##STR4##
A suitable catalyst for this hydrogenation is palladium preferably on a solid support, preferably 5% palladium on charcoal. The reaction is carried out in a nonaqueous polar solvent such as dimethylformamide and at a temperature in the range of from about 0° to 50° C., preferably at about room temperature and at ambient pressure. Isolation of the product can be carried out in the same manner as from the above fermentation, i.e. gel chromatography such as with silica gel 60 and crystallization.
The saturated product of formula IV is then reacted with a p-tolyl or methyl sulfonyl halide at a temperature in the range of from 78° to 0° C., preferably at about -10° C. The reaction is conveniently carried out in a nitrogeneous organic solvent such as pyridine. A preferred reagent for this reaction is p-toluenesulfonyl chloride. The resulting product of this reaction, which can be isolated in the same manner as previously described for compounds above, has the formula ##STR5## where X is methyl or p-tolyl, preferably p-tolyl.
A preferred embodiment of a compound of formula V is thus (5β)-7α-hydroxy-22-([4-methylphenyl]sulfonyl-oxy)-23,24-bisnorcholan-3-one.
In the next step of the process of the present invention a compound of formula V is reacted with sodium di-C 1-3 -alkyl malonate, preferably dimethylmalonate in a polar non-aqueous solvent such as dimethylformamide at a temperature in the range of from 0° to 100° C., preferably at about 50° C. in an inert atmosphere with exclusion of moisture. The sodium di-C 1-3 -alkyl malonate can be prepared in situ by adding the malonate to a solution of sodium hydride in dimethylformamide and stirring at 40°-50° C. Isolation of the end product is carried out in analogy to the procedures described previously. The resulting product has the formula ##STR6## where Y is C 1-3 -alkyl, preferably methyl. A preferred embodiment of a compound of formula VI is thus (5β)-24-norcholan-7α-ol-3-one-23,23-dicarboxylic acid dimethyl ester.
The compound of formula VI is then reduced to the corresponding 3-hydroxy compound of the formula ##STR7## where Y is C 1-3 -alkyl, preferably methyl. A preferred embodiment of a compound of formula VII is (5β)-24-norcholane-3α,7α-diol-23,23-dicarboxylic acid dimethyl ester.
The reduction procedure is accomplished by using a conventional chemical reducing agent such as sodium borohydride in an aqueous C 1-3 alkanol solvent such as 95% ethanol at a temperature in the range 0° to 50° C., preferably at room temperature under an inert atmosphere. The reaction product can be isolated from the reaction mixture by acidifying and extracting with a halocarbon solvent such as dichloroethane. Removal of the solvent provides the product in crude form which can be used without further purification in succeeding steps.
The diol of formula VII is then saponified by refluxing in the presence of strong base, i.e. barium hydroxide so as to provide, after work-up and acidification a dicarboxylic acid of the formula ##STR8## which is (5β)-24-norcholane-3α,7α-diol-23,23-dicarboxylic acid.
In the final step of this embodiment of process of the invention the dicarboxylic acid of formula VIII is thermally decarboxylated by heating the formula VIII compound at a temperature of about 190°-205° C. under an inert atmosphere so as to produce the desired end product chenodeoxycholic acid of formula I above.
In an alternate process embodiment of the present invention a compound of formula V can be treated with a chemical reducing agent such as a lithium aluminum alkoxide hydride, preferably lithium aluminum tri-t-butoxyhydride, at a temperature in the range of from about -78° C. to room temperature, preferably at about -10° C. in an inert organic solvent such as a cyclic ether, preferably tetrahydrofuran and under an inert atmosphere so as to produce a diol of the formula ##STR9## where X is as above.
A preferred embodiment of a compound of formula IX is 2,2-([4-methylphenylsulfonyl]oxy)-23,24-bisnorcholane-3α, 7α-diol.
In the next process step the compound of formula IX is reacted with a greater than twofold molar excess of an acylating agent conventionally employed as a hydroxy protecting group in steroid chemistry so as to prepare the corresponding diacyl compound. Suitable acylating agents include the C 2-6 lower alkanoic acid anhydrides, preferably acetic anhydride. The acylation is readily carried out in a suitable organic solvent such as pyridine in the presence of an amine base such as 4-dimethylaminopyridine. The resulting diacyl product has the formula: ##STR10## where X is as above and R is acyl.
A preferred embodiment of a compound of formula X is 22-([4-methylphenyl)sulfonyl]oxy)-23,24-bisnorcholane-3α,7α-diol 3,7-diacetate.
The diacyl compound of formula X is then reacted with a sodium di-C 1-3 -alkyl malonate, preferably diethylmalonate in direct analogy to the previously described conversion of compound V to compound VI above so as to produce a compound of the following formula: ##STR11## where R and Y are as above.
A preferred embodiment of a compound of formula XI is 3α,7α-(diacetoxy)-24-norcholane-23,23-dicarboxylic acid diethyl ester.
Conversion of a compound of formula XI to a dicarboxylic acid of formula VIII described above is readily accomplished by saponification with a strong base such as an alkali metal hydroxide solution, preferably potassium hydroxide at elevated temperature, preferably at reflux. The reaction can be carried out in the presence of one or more lower alkanols as solvent such as, for example methanol, isopropanol or mixtures thereof.
The process and intermediates of the present invention are further illustrated by reference to the following Examples.
EXAMPLE 1
(5β)-7α,22-Dihydroxy-23,24-bisnorchol-4-en-3-one (7-alpha-OH-3-KC)
Fermentation Procedures
Cultures were maintained on the following media: bacteria, glucose nutrient agar; fungi, Sabouraud Dextrose agar (SD) (Difco); actinomycetes, starch-casein agar. Vegetative inoculum was prepared in either Sabouraud Dextrose broth (Difco) or in the medium used in the fermentation stage. The latter was composed of: Edamin (Sheffield Chemical Co.), 20 g; cornsteep liquor (Corn Products Co.), 3 g.; dextrose, 50 g.; and distilled water to a final volume of 1 liter. The pH was adjusted to 5.0 with HCl prior to sterilization by autoclaving. The fermentations were carried out either in 250 or 500 ml Erlenmeyer flasks containing 50 and 100 ml of medium respectively. The flasks were inoculated with vegetative growth (5%) from cultures grown in the inoculum medium for 72 hours at 28° C. on a 250 RPM rotary shaker (5 cm eccentricity). Unless otherwise indicated, the same conditions apply for the fermentation stage. The 3-keto-bisnorcholenol (3-KC) was added after 48 hour incubation either as a solution in 3A ethanol, or as a 5% suspension in 0.1% solution of Tween 80 (Atlas Chemical Industries) prepared by sonic treatment (Bronson Sonifier Cell Disruptor 200). Incubation was continued for up to 120 hours after addition of the substrate.
Seventy-five species of fungi representing thirty-two genera, six species of actinomycetes, representing five genera, and eight species of gram-negative bacteria belonging to three genera, and three species of Gram positive bacteria belonging to one genus (152 cultures in total), were tested for their ability to convert 3-KC to 7-alpha-OH-3-KC. As a result of this screening, only nine cultures were found capable of the desired transformation. Other members of these same genera, and, in some cases, other strains of the same species, appeared to be incapable of converting the substrate to the desired product (Table 1).
______________________________________ SourceCulture Code 7-α-OH-3-KC______________________________________Botryodiplodia theobromae IFO 6469 +Botryodiplodia theobromae DSM 62-678 +Botryodiplodia theobromae DSM 62-679 +Lasiodiplodia theobromae(Botryodiplodia theobromae) ATCC 28570 +Lasiodiplodia theobromae(Diplodia natalensis) ATCC 9055 0Lasiodiplodia theobromae(Diplodia theobromae) ATCC 10936 0Lasiodiplodia theobromae(Botryodiplodia theobromae) ATCC 16931 0Lasiodiplodia theobromae(Botryodiplodia theobromae) ATCC 26123 0Diplodia natalensis ATCC 9055 0Diplodia zeae QM 6983 0Botryodiplodia malorum CBS 134.50 0Botryosphaeria ribis ATCC 22802 +Botryosphaeria berengeriana ATCC 12557 +Botryosphaeria rhodina CBS 374.54 +Botryosphaeria rhodina CBS 287.47 +Botryosphaeria rhodina CBS 306.58 +Botryosphaeria corticis ATCC 22927 0______________________________________
Shake flask experiments on Botryodiplodia theobromae IFO 6469 indicated that product yields were increased by addition of 2,2'-dipyridyl, a chelating agent, to final concentrations ranging from 0.5×10 -4 M to 0.75×10 -3 M.
Also, it was noted that at the time of substrate addition, 48 h., the culture was depleted of the glucose originally present. Addition of either glucose or sucrose (final concentration 5%) at this time appeared to slow degradation of 3-KC and 7-alpha-OH-3-KC. Other small improvements in yield were also achieved by lowering the temperature to 24° C. at 48 h., and by using a 5% suspension of substrate prepared by sonic treatment in 0.1% Tween 80. By combining all of these improved conditions, a 25% conversion of 3-KC to 7-alpha-hydroxy-3-KC was achieved with 46% of unreacted 3-KC still present (analyses by high pressure liquid chromatography (HPLC)).
The most striking improvement in yield was found as a result of addition of absorbants to the fermentation. When Amberlite XAD-7 was added at 0.3-0.6% to fermentations of Botryodiplodia theobromae IFO 6469 strain, a substantial increase in the yield of 7-alpha-OH-3-KC resulted. This increase of product formation was evident at 3-KC concentrations of up to 1 g/liter; at higher substrate concentrations XAD-7 was without effect. Similarly, no further stimulation of yields were obtained with XAD-7 in amounts above 0.6%. Before use, the XAD-7 resin was refluxed in acetone for 21/2 hours, rinsed repeatedly with distilled water until all traces of acetone and color were gone, and dried at 40° C.
The 7-alpha-hydroxylation of 3-KC was also carried out with the said Lasiodiplodia theobromae culture with minor modifications of the basic fermentation procedures. HPLC analyses of an extract of a fermentation carried out with this organism indicated a 25% yield with 22% of remaining substrate.
Identification of the transformation product of 3-KC was performed on material isolated from both cultures as described below.
Isolation of 7-alpha-OH-3-KC
Two liters of harvested whole culture broth from a fermentation which had been charged with 1 gram of 3-KC, was extracted twice, each time with 1 liter of ethyl acetate. The extracts were combined, concentrated to 0.5 liter and filtered through glass wool. The filtrate was evaporated to dryness and the residue redissolved in 150 ml of hot ethyl acetate. After cooling to room temperature an insoluble fraction was again removed by filtration. The filtrate was concentrated by evaporation to 35 ml and applied to a 29 mm dia. column containing 200 g of silica gel G-60. The column was developed with ethyl acetate and the 7-alpha-OH-3-KC rich fractions combined, concentrated and rechromatographed on silica gel G-60 developed with methylene chloride, ethyl acetate, hexane (1:1:1). The 7-alpha-OH-3-KC rich fractions were again combined, the solvent removed by evaporation and the product obtained by crystallization from a small volume of ethyl acetate (220 mg from the Botryodiplodia culture; 185 mg from the Lasiodiplodia culture). Identity as 7-alpha-OH-3-KC was established by comparison with an authentic synthetic sample of 7-alpha-OH-3-KC: m.p. 199°-200° C. (authentic sample 197.5°-200° C.); mixture m.p. (undepressed); NMR, mass spectrum and specific rotation.
Analyses
Unless otherwise indicated, quantitative analyses for 3-KC and 7-alpha-OH-3-KC were by thin-layer chromatography (TLC). These were carried out on ethyl acetate extracts of fermentation samples. The extracts were evaporated to dryness at 40° C. and redissolved in a volume of 3A ethanol ten times smaller than the original sample volume. Chromatography was on silica gel F 254 TLC plates (E. Merck, Darmstadt, Germany) developed with ethyl acetate. The developed plates were air-dried and the spots visualized under short wavelength UV light (254 nm). The R f values obtained in this TLC system were 0.75 and 0.36 for substrate and product respectively. Minor amounts of products having R f values lower than 0.36 can be seen in the chromatogram, and their separation from the desired product can be improved by repeated development with the same solvent system.
Quantitative assays of the materials in the spots were made by carefully scraping the area of the spot from the plate into a test tube, and eluting overnight with 5 ml of 3A ethanol. The absorbance of the eluate was measured at 240 nm in a Gilford 250 spectrophotometer, and compared with values from a standard curve obtained by chromatographing known amounts of authentic 3-KC and 7-alpha-OH-3-KC. TLC results were also quantitated by measuring fluorescence quenching of the spots (Zeiss TLC Spectrophotometer, PMQII).
High pressure liquid chromatographic HPLC) analyses were carried out on a silica gel (SR-I-10) column developed with 20% dioxane in methylene chloride. The column was monitored with a 254 nm detector.
EXAMPLE 2
(5β)-7α,22-Dihydroxy-23,24-bisnorcholan-3-one
To 1.92 g (0.0055 mol) of 7α,22-dihydroxy-23,24-bisnorchol-4-en-3-one dissolved in 25 ml of freshly distilled, dry dimethylformamide was added 0.19 g of 5% palladium on carbon. The suspension was stirred under a hydrogen atmosphere at room temperature for 5.5 hr. Hydrogen uptake ceased at 108 ml (theory 124 ml). The catalyst was removed by filtration and was washed with 200 ml of ethyl acetate. The filtrate was poured into 1 l. of water and was extracted with 5×250 ml of ethyl acetate (saturated brine was added to aid break-up of emulsions). The combined ethyl acetate extracts were washed with 5×250 ml of water followed by 2×250 ml of saturated sodium chloride. The ethyl acetate was dried over sodium sulfate and evaporated in vacuo to give 2.13 g of crude (5β)-7α,22-dihydroxy-23,24-bisnorcholan-3-one. The total product was chromatographed on 150 g of silica gel 60 and eluted with ethyl acetate. The product fraction weighing 1.7 g was rechromatographed on 300 g of silica gel 60 and eluted with a solvent mixture of ethyl acetate/methylene chloride (2:1) giving 1.29 g (67%) of (5β)-7α,22-dihydroxy-23,24-bisnorcholan-3-one. The analytical sample was crystallized from ethyl acetate, mp 132°-133° C.
[α] 25 D=+15.4 (c 1.01, CHCl 3 ).
Calc for C 22 H 36 O 3 : C, 75.82; H, 10.41, Found: C, 76.10; H, 10.69.
EXAMPLE 3
(5β)-7α-Hydroxy-22-([(4-methylphenyl)sulfonyl]-oxy)-23,24-bisnorcholan-3-one
To 1.0 g (0.00286 mol) of (5β)-7α,22-dihydroxy-23,24-bisnorcholan-3-one dissolved in 20 ml of absolute pyridine cooled to -10° C. was added 2.18 g (0.0114 mol) of p-toluenesulfonyl chloride. The solution was stirred for 1 hr at -10° C. and then placed in a refrigerator overnight. The reaction was then poured into 400 ml of a 0.25 N sodium bicarbonate solution and extracted with 4×100 ml of ethyl acetate. The combined ethyl acetate extracts were washed successively with 3×100 ml of 1 N sodium bicarbonate, 3×100 ml of water, 3×100 ml of 1 N hydrochloric acid, and finally with water until neutral. After drying with sodium sulfate, the ethyl acetate was evaporated to give 1.54 g of crude product which was purified by column chromatography on 150 g of silica gel 60. Elution with benzene/ethyl acetate (4:1) gave 1.15 g (80% yield) of (5β)-7α-hydroxy-22-([(4-methylphenyl)sulfonyl]-oxy)-23,24-bisnorcholan-3-one. The analytical sample was recrystallized from toluene/heptane, mp 157°-160° C.,
[α] 25 D+12.7 (c 0.994, CHCl 3 ).
Anal. Calcd: C, 69.29; H, 8.42, Found: C, 69.55; H, 8.47.
EXAMPLE 4
(5β)-24-Norcholan-7α-ol-3-one-23,23-dicarboxylic acid dimethyl ester
To 3 of dry dimethylformamide at room temperature under an argon atmosphere was added 30 mg (0.0007 mol) of 57% sodium hydride followed by 0.066 g (0.0005 mol) of dimethyl malonate dissolved in 1 ml of dimethylformamide. After stirring for 1.5 hr at 40°-50° C., 0.251 g (0.0005 mol) of (5β)-7α-hydroxy-22-([(4-methylphenyl)sulfonyl]-oxy)-23,24-bisnorcholan-3-one was added. The reaction was stirred for 1 hr at room temperature, warmed to 50° C. in an oil bath for 18 hr, and then poured into 25 ml of water. Extraction with 4×10 ml of ethyl acetate followed by washes with water and saturated brine gave, after drying over sodium sulfate and evaporation, 0.20 g of crude product. After chromatography on 20 g of silica gel 60 and elution with a mixture of dichloromethane/ethyl acetate (2:1), 0.041 g (17% yield) of (5β)-24-norcholan-7α-ol-3-one-23,23-dicarboxylic acid dimethyl ester was obtained.
EXAMPLE 5
(5β)-24-Norcholane-3α,7α-diol-23,23-dicarboxylic acid dimethyl ester
To a solution of 0.195 g (0.00042 mol) of (5β)-24-norcholan-3-one-23,23-dicarboxylic acid dimethyl ester in 12 ml of 95% ethanol at room temperature under an argon atmosphere was added 0.025 g (0.00063 mol) of sodium borohydride. The reaction mixture was allowed to stir for 2 hrs, then poured into 50 ml of water containing 4 ml of 1 N hydrochloric acid. The aqueous solution was extracted with dichloromethane and the combined extracts dried over sodium sulfate and evaporated to give 0.195 g of the above-captioned crude diol.
EXAMPLE 6
(5β)-24-Norcholane-3α,7α-diol-23,23-dicarboxylic acid
To a solution of 0.195 g of crude (5β)-24-norcholane-3α,7α-diol-23,23-dicarboxylic acid dimethyl ester in 5 ml of ethanol was added 2 ml of water followed by 0.80 g of barium hydroxide. The solution was heated at reflux for 3 hrs, cooled to room temperature, and then acidified by the addition of 1 N hydrochloric acid. After extraction with dichloromethane and drying, the solvent was evaporated to give 0.135 g of (5β)-24-norcholane-3α,7α-diol-23,23-dicarboxylic acid.
EXAMPLE 7
Chenodeoxycholic Acid
In a round-bottom flask under an argon atmosphere, 0.135 g (0.00031 mol) of (5β)-24-norcholane-3α,7α-diol-23,23-dicarboxylic acid was heated for 10 min at 190°-205° C. Gas evolution was observed. After cooling, the residue was chromatographed on 10 g of silica gel 60 and eluted with 10% ethanol in ethyl acetate to give 0.045 g of chenodeoxycholic acid as a glass. Tlc and nmr were identical with an authentic sample.
EXAMPLE 8
22-([(4-methylphenyl)sulfonyl]oxy)-23,24-bisnorcholane-3α,7α-diol
To 0.350 g (0.00069 mole) of (5β)-7α-hydroxy-22-([(4-methylphenyl)sulfonyl]oxy)-23,24-bisnorcholan-3-one in 10 ml of dry tetrahydrofuran cooled to -10° C. under an argon atmosphere is added dropwise 0.391 g (0.00138 mole) of lithium aluminum tri-t-butoxyhydride dissolved in 5 ml of dry tetrahydrofuran. After 11/2 hr, the reaction was quenched by the addition of 2 ml of 1 N hydrochloric acid. The tetrahydrofuran was removed in vacuo. The residue was taken up in 50 ml of water and extracted with 3×40 ml of ethyl acetate. The combined ethyl acetate extracts were washed with water until neutral and dried over anhydrous sodium sulfate. The mixture was filtered and solvent removed in vacuo to give 0.374 g of crude product. This was chromatographed on 37 g of silica gel 60 and eluted with ethyl acetate to give 0.290 g (88%) of 22-([(4-methylphenyl)sulfonyl]oxy)-23,24-bisnorcholane-3α ,7α-diol.
The analytical sample was recrystallized from isopropanol/water. Mp 87°-89° C.
[α] 25 D=+8.25 (c 0.9933, CHCl 3 ).
Calcd. for C 29 H 44 O 5 S: C, 69.01; H, 8.79; S, 6.35, Found: C, 69.21; H, 8.88; S, 6.07.
EXAMPLE 9
22-([(4-methylphenyl)sulfonyl]oxy)-23,24-bisnorcholane-3α,7α-diol 3,7-diacetate
A mixture of 0.290 g (0.00049 mole) of 22-([(4-methylphenyl)sulfonyl]oxy)-23,24-bisnorcholane-3α,7α-diol, 0.6 ml (0.0064 mole) of acetic anhydride, 0.6 ml (0.0074 mole) of dry pyridine, 0.003 g (0.000025 mole) of 4-dimethylaminopyridine, and 10 ml of dry toluene was stirred overnight under an argon atmosphere. The mixture was acidified with 50 ml of 0.5 Normal hydrochloric acid and extracted with 3×20 ml of ethyl acetate. The ethyl acetate extracts were washed with water until neutral, then dried over anhydrous sodium sulfate. The mixture was filtered and solvent removed in vacuo to give 0.311 g of crude product. This was recrystallized from methanol to give as a first crop material 0.2577 g (76%) of 22-([(4-methylphenyl)sulfonyl]oxy)-23,24-bisnorcholane-3α,7α-diol 3,7-diacetate. The mother liquor, after evaporation gave 0.065 g (19%) of product which by tlc appeared to be greater than 95% pure. The analytical sample was recrystallized from methanol. Mp 174°-175° C.
[α] 25 D+7.41 (c 0.8768, CHCl 3 ).
Calcd for C 33 H 48 O 7 S: C, 67.32; H, 8.22, Found: C, 67.34; H, 8.33.
EXAMPLE 10
3α,7α-(diacetoxy)-24-norcholane-23,23-dicarboxylic acid diethyl ester
0.264 g (0.0055 mole) of a 50% oil dispersion of sodium hydride was washed under an argon atmosphere with 3×3 ml of dry pentane. Then, 7.5 ml of dry toluene was added. 1.056 g (0.0066 mole) diethylmalonate in 5 ml of dry toluene was added dropwise, then heated to reflux and 1.1776 g (0.0020 mole) of 22([(4-methylphenyl)sulfonyl]oxy)-23,24-bisnorcholane-3α,7α-diol 3,7-diacetate in 10 ml of dry toluene was added dropwise. The mixture was heated to reflux for 20 hours. An additional 0.49 g (0.003 mole) of diethylmalonate and 0.050 g (0.001) mole of washed (pentane) sodium hydride was added and the mixture heated to reflux. After five hours, the cooled mixture was poured into 100 ml of water and extracted with 3×60 ml of ethyl acetate. The combined ethyl acetate extracts were washed with water until neutral and dried over anhydrous sodium sulfate. The mixture was filtered and solvent removed in vacuo leaving a 1.114 g residue. This was chromatographed on 100 g of silica gel 60 and eluted with methylene chloride/ethyl acetate (9:1) to give 0.849 g (76%) of 3α,7α-(diacetoxy)-24-norcholane-23,23-dicarboxylic acid diethyl ester. The analytical sample was recrystallized from methanol/water. Mp 121.5°-123° C.
[α] 25 D+23.97 (c 1.0679, CHCl 3 ).
Calcd for C 33 H 52 O 8 : C, 68.72; H, 9.09, Found: C, 68.92; H, 9.00.
EXAMPLE 11
3α,7α-Dihydroxy-24-norcholane-23,23-dicarboxylic acid
To a solution of 3 ml of methanol, 5 ml of isopropanol and 0.779 g (0.0139 mole) of potassium hydroxide is added 0.350 g (0.0006 mole) of 3α,7α-(diacetoxy)-24-norcholane-23,23-dicarboxylic acid diethyl ester. The mixture was heated to reflux under an argon atmosphere for 4 hrs then left to stir overnight at room temperature. The alcohol solvents were removed in vacuo and the mixture poured into 50 ml of water and washed with 3×25 ml of diethyl ether. The aqueous layer was acidified and the precipitate collected by suction filtration. 0.252 g (96%) of the crude diacid was obtained, Mp 203° C., with decomposition. This was used directly in the next step without further purification.
EXAMPLE 12
Chenodeoxycholic Acid
A mixture of 0.125 g (0.00028 mole) of 3α, 7α-dihydroxy-24-norcholane-23,23-dicarboxylic acid, 5 ml of xylene and 1 ml of dry pyridine was heated to reflux for one hour. The mixture was cooled, solvents were removed in vacuo and the residue dissolved in 25 ml of ethyl acetate. The ethyl acetate solution was washed with 3×10 ml of 1 N hydrochloric acid, then with water until neutral. The ethyl acetate extract was dried over anhydrous sodium sulfate, filtered and solvent removed in vacuo to give 0.111 g of crude product. This was recrystallized from hexane/ethyl acetate to give (first crop material), 0.086 g (76%) of product which had the same spectral properties as authentic chenodeoxycholic acid and gave no melting point depression. An analytical sample was prepared by chromatography on silica gel 60 eluting with methylene chloride/methanol/hexane, (2:1:1), then recrystallized from ethyl acetate. | A multi-step synthesis of chenodeoxycholic acid from 3-keto-bisnorcholenol, a compound readily obtained from the abundant plant sterol β-sitosterol, is described. A key step in the synthesis is the stereoselective microbial introduction of the 7-alpha hydroxy group into 3-keto-bisnorcholenol. | 2 |
BACKGROUND OF THE INVENTION
[0001] The invention is based on a priority application EP 02360160.2 which is hereby incorporated by reference.
[0002] The invention relates to a method for the asynchronous transmission of data packets in telecommunication networks with a bit rate B, and transmitters and receivers for performance of the method.
[0003] The invention further relates to a method for the synchronous transmission of data packets in telecommunication networks, where the data payload to be transmitted is embedded in a frame structure according to standard G.709.
[0004] Such a method for asynchronous transmission of data packets and a corresponding receiver unit are known from a publication by H. Nishizawa et al., 26th European Conference on Optical Communication, ECOC 2000, Sep. 3-7, 2000 Munich, Germany, Paper 10.4.8, vol 4, pages 75 ff.
[0005] Data transmission with a high information flow i.e. a high number of binary information units (bits) to be transmitted per time unit, in particular at 9.95328 GBit/s (10 GBit/s) and more, takes place in optical information networks primarily by point-to-point connections. Here in the simplest case signals are passed continuously from a transmitter unit of a first network point via a light waveguide exclusively to a receiver in a second network point. Even if occasionally no data needs to be transmitted between the two network points, a signal flow is maintained. As a result the receiver can maintain its read phase and read bit position (i.e. synchronization with the transmitter unit) and the limit level (i.e. the threshold intensity below which signal is perceived as “0” and above which the signal is perceived as “1”). This method of data transmission is therefore known as “synchronous”.
[0006] At the receiver the data are unpacked and read in order to determine the destination of the data packet. The information is then repacked into a data packet which is then passed by the transmitter unit of the second network point to a third network point, where this third network point is closer to the destination of the data packet than the second network point.
[0007] An alternative to this is data transmission in burst mode; this is known as “asynchronous” data transmission. It is suitable in particular for IP data traffic (internet) in which short data packets must be exchanged between constantly changing transmitter and receiver pairs. Lines from various other network points merge at one network point (between transmitter and receiver). An incoming data packet on one of the lines is passed via an optical switch directly physically (i.e. without reading) to another line of the network point. This line is selected according to the destination of the data packet, where this destination information is taken from a short header data packet. The header is the only part read; its transmission can be time-delayed or take place on a separate channel.
[0008] At such a network point the times of data packet input and transfer alternate with periods of darkness (i.e. no input of signals). In times of darkness where applicable a switching of the output line takes place for the next data packet to be transferred.
[0009] The receiver of a burst mode network has two difficulties to overcome: firstly not only the frequency (bit rate) but also the phase of an incoming signal is not known. The receiver must therefore be synchronized to each incoming signal packet. Secondly the amplitudes of the incoming signal packets vary from transmitter to transmitter, for example because of attenuation effects in different lengths of signal line running to the network point. Therefore the limit level for each incoming data packet must be recalibrated. The faster switching can take place between two different transmitters, the higher the possible data throughput.
[0010] Consequently to receive burst mode signals, special receivers are required. Such a burst mode receiver is described by Nishizawa et al., idem. At the receiver are present both a Manchester-coded optical data packet and an extraction signal. The optical data packet is amplified with an EDFA preamplifier and supplied to a differential photodetector. Its signal is linear-amplified, high-pass-filtered and supplied to an electrical limiting amplifier. The data packet and extraction signal are finally analysed with a digital ring oscillator and a decider circuit so that the original data packet is present at the receiver output as an electrical non-return to zero (NRZ) signal. The optical data packets used consist of short prefix bits for synchronisation and the data payload. The extraction signal supplied to the receiver in parallel to the optical signal indicates the prefix period.
[0011] Such a burst mode receiver in comparison with signal receivers for continuous (synchronous) signal transmission is complex and expensive in structure. Problems occur with detecting the start of the data payload, for which an additional control signal, the extraction signal, is required.
SUMMARY OF THE INVENTION
[0012] The object of the invention is to construct the burst mode method such that a signal receiver can easily and directly detect the data payload of a data packet, and also the signal receiver can be constructed largely on the basis of known hardware technology from receivers of continuous point-to-point connections.
ADVANTAGES OF THE INVENTION
[0013] This is achieved in a method according to the invention in that the asynchronous transmission of data packets in telecommunication networks with a bit rate B which includes the following steps:
[0014] (a) methoding of the data to be transmitted such that the probability of the occurrence of a 0 or 1 state in the data stream at each bit position is approximately equal and independent of other bit positions (scrambling);
[0015] (b) waiting for a guard band time t gb , transmission of a synchronisation sequence during time t sy , transmission of a synchronisation word during time t co , and transmission of the data payload;
[0016] (c) detection of a synchronisation sequence and synchronisation to this in a receiver;
[0017] (d) detection of the start of the data packet by detection of the synchronisation word in the receiver;
[0018] (e) reception of the data payload in the receiver.
[0019] To receive data packets structured according to the invention, a receiver originally designed for continuous signal reception can be adapted according to the invention by raising the lower limit frequency f u of the receiver. This avoids a memory effect of the receiver beyond the packet limits. However as a result signal sequences with a high DC part (i.e. sequences with many zeroes or many ones in direct succession) are only received disrupted. For this reason according to the invention a scrambling method of data encryption is applied to avoid such sequences.
[0020] For this reason according to the invention at least one scrambling method is applied which irrespective of the nature of the data payload guarantees the even and independent distribution of the bits (in the example of a fax, almost all “bits” are “white” and only a few are “black”; only by scrambling is an evenly distributed 0/1 sequence achieved). Channel coding is better than scrambling. Here additional bits are inserted in the data stream so that undesirable bit sequences can generally be excluded (scrambling cannot exclude such undesirable sequences, merely makes them extremely improbable according to length). Manchester coding is an extreme example of channel coding in which for each bit to be transmitted, an extra bit is transmitted. This guarantees a bit change in the signal at the latest in the third successive signal bit. However the data throughput is also halved.
[0021] An alternative coding provides for example that a sequence of 8 information bits (or a comparable order of magnitude) is transmitted in a 10-bit signal, where bit 9 and bit 10 differ, i.e. are approximately 0 and 1. As a result a bit change in the signal is guaranteed at the latest after 10 bits. This coding reduces the data throughput by just 20%.
[0022] By scrambling or coding, the DC proportion of the signal is reduced so far that cutting out the lower-frequency signal parts below the lower limit frequency causes no information loss, i.e. in the coded signal there are no lower-frequency sections.
[0023] In order at a lower limit frequency f u of B/300 to achieve the same bit error rate (typically 10 −12 ) as at a non-raised lower limit, a signal-to-noise ratio better then 3 dB is required. This con be achieved by raising the transmission power. Higher lower limit frequencies lead to a strong rise in bit error rate irrespective of the signal-noise ratio and hence to a greater probability of packet loss.
[0024] During the synchronisation sequence t sy the receiver has the opportunity to tune into the data packet. This is utilised in particular to determine the phase of the incoming signal and synchronise the receiver to this, and to determine the intensity of the incoming signal in order to establish the limit level. A simple synchronisation sequence consists of sequence 101010 . . . etc.
[0025] The decision threshold (limit level) is set during the synchronisation sequence to the mean signal value. The first bits may under some circumstances not be detected and be lost, as during this period certain recognition of 0 and 1 is not possible. The minimum tuning time t sy arises from the tuning time for the high-pass of the receiver over f u according to t Sy≧ 1/(2*π*f u ), where f u =B/300 and t sy ≧53/B. In this case the synchronisation sequence must be at least 53 bits long; in practice 100 bits is selected which at B=10 GBit/s corresponds to a t sy of 10 ns.
[0026] By including a synchronisation word, the start of the data payload is defined. This is necessary as an undetermined number of bits at the packet start are lost during synchronisation. The synchronisation word should have a narrow auto-correlation function and the greatest possible code interval for both the synchronisation sequence (e.g. 101010 . . . ) and for the signal pause (0000 . . . ). A 16-bit synchronisation word is not generally sufficient. The inclusion of the synchronisation word makes the control signal (extrusion signal) to identify the start of the data payload superfluous and no time-critical switch methodes need take place.
[0027] The guard band time t gb is necessary to give the receiver, after reception of a packet with maximum transmission power, time to detune so that then a packet with the minimum permitted transmission power can still be detected reliably. At a lower limit frequency f u =B/300 and power fluctuation of 7 dB, the guard band t gb corresponding to 150 Bit is given, i.e. at B=10 GBit/s approx. 15 ns.
[0028] The receiver specifies a minimum guard band which must be observed by the synchronicity of the higher system consisting of several transmitters and optical switches.
[0029] This higher system is a mesh structure of network points which in the case of an optical burst mode network consists of the multiplicity of light waveguides, where applicable with amplifier elements, and optical switches. At least one line leads from one of the optical switches to the receiver. Star, ring and tree-like structures are possible.
[0030] The size of the data payload proportion in the data packet is in principle not restricted with the method according to the invention or the receiver according to the invention. Both fixed packet lengths and variable packet lengths are possible. The size of the data payload proportion however does influence the channel utilisation i.e. the proportion of the data payload transport in the entire signal traffic. The longer the data payload section of the data packet, the better (higher) the channel utilisation. In a 10 GBit/s data network with an average pause of 50 ns between two packets and a synchronisation sequence of 12 ns and a data payload length of 1 μs (10000 bits), the channel utilisation is approximately 95%.
[0031] In a particularly preferred variant of the method according to the invention, the data packets are transmitted by a high bit-rate, optical data transmission with B≧9.95328 Gigabit/second. The standard of 9.95328 GBit/s is described in brief as 10 Gbit/s. At such high bit rates, the advantages of the invention are particularly clear. Optical systems are able to achieve such high bit rates.
[0032] A variant of the method according to the invention in which the data packets are transferred in burst mode is particularly preferred. This is the conventional method of asynchronous signal transmission in which the invention is particularly applicable.
[0033] A method variant according to the invention provides that to method the data in step (a) a coding method is used in which the power spectrum of the coded data does not have any intensity at frequencies below 0.01*B, in particular no intensity below 0.003*B. In the case of B≈10 Gbit/s these frequencies correspond to 100 MHz and 30 MHz. This minimises information loss in the receivers on data transmission as the data signal is applied via a high-pass at the receiver according to the invention.
[0034] The method according to the invention in a preferred variant provides that the data packets are transmitted by several transmitters on a network element which passes the data packets in time multiplex on a common output line to a selected receiver. Further network elements can be connected to the network element as transmitters. Only when the network element is linked with several transmitters is burst mode operation fully applicable. This achieves a good data throughput.
[0035] In the structure of the two previous method variants of the method according to the invention for asynchronous data transmission, the network element causes a temporal separation of at least t gb between an end of a first data packet and the start of a second transmitted data packet. This prevents collision of data packets at the receiver and the receiver is sufficiently relaxed (detuned) before a new data packet reaches it.
[0036] A particularly preferred variant of the method according to the invention provides that the guard band is selected as t gb ≧100/B. This guard band is sufficient for the receiver, after receiving a data packet with high signal intensity, to return to its starting condition i.e. detune, so that after t gb a signal with low intensity is reliably detected. The size of t gb according to the invention thus improves the reliability of data transfer.
[0037] In a preferred method variant the lower limit frequency of the receiver input lies between 0.0005*B and 0.005*B, preferably between 0.001*B and 0.003*B. At B≈10 GBit/s this corresponds to frequencies of 5 MHz, 50 MHz, 10 MHz and 30 MHz. Due to the lower limit frequency of the receiver input set according to the invention, a conventional receiver intended for continuous signal reception can be used for the reception of packets. The values here constitute an optimum range of data security and data throughput.
[0038] The scope of the present invention also includes a transmitter for transmission of data packets in the above method according to the invention and its variants, where means are provided for the performance of steps (a) and (b). Thus data packets according to the invention can be generated on a signal line.
[0039] The invention further includes a receiver for the transmission of data packets in the above method according to the invention and its variants, where means are provided for performance of steps (c), (d) and (e). Thus data packets according to the invention can be read from the signal line.
[0040] An embodiment of this receiver provides that a coupling capacitor is provided as a high-pass to raise the lower limit frequency of the receiver input. This shortens the detuning time of the receiver and recreates the readiness to record a new data packet quickly after the end of the previous data packet.
[0041] The invention also includes a method for synchronous transmission of data packets in telecommunication networks, where the data payload to be transmitted is embedded in a frame structure according to standard G.709, wherein
[0042] (i) in the ODUk overhead is inserted a connection code in coded form which allocates the data packet concerned to a particular network connection,
[0043] (ii) and that within a switching point the FEC part of the frame structure of the data packet is modified so that between the end of the previous data packet and the start of the immediately following data packet is a guard band time t gb >20 ns and that an internal control signal to synchronize subsequent receiver units is generated within the switching center on the data packet.
[0044] Further advantages of the invention arise from the description and drawings. Also the features according to the invention stated above and further features to be listed can be applied individually or together in any combination. The embodiments shown and described should not be interpreted as a complete list but rather serve as examples to explain the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] The invention is shown in the drawing and explained in more detail with reference to embodiment examples. Here:
[0046] [0046]FIG. 1 a : shows the frame structure of a data packet according to standard G.709;
[0047] [0047]FIG. 1 b : shows the transmission sequence of a data packet to standard G.709;
[0048] [0048]FIG. 2: shows the diagrammatic structure of a connection point according to the invention for the transmission of data according to standard G.709 modified according to the invention;
[0049] [0049]FIG. 3: shows the internal data format of standard G.709 modified according to the invention.
DETAILED DESCRIPTION
[0050] The asynchronous transmission of data packets (packet transmission) according to the invention causes a loss of channel capacity due to times t gb (guard band) and t sy (synchronisation sequence). (The synchronisation word is ignored in this assessment as it is negligibly short compared with t gb and t sy ). The channel utilisation is therefore:
E=t pay /( t gb +t sy +t pay ) (1)
[0051] (t pay =period of net data payload).
[0052] A statistically independent and evenly distributed bit sequence (similar to scrambling) has a lower limit frequency f u of 0 Hz. This is impractical for technical systems. The lower limit frequency can be raised to {fraction (1/300)}th of the bit rate provided a loss of 3 dB in the signal-to-noise ratio is accepted, which has been proven by simulation calculations.
f u ≦({fraction (1/300)})*1 /T (2)
[0053] (T=length of one bit, bit rate B=1/T, at B=10 GBit/s T=100 ps).
[0054] The tuning at the packet start must take place within t sy . The minimum tuning time of the simple high-pass at the receiver input is approximately equal to time constant Tau which arises from the lower limit frequency.
t sy ≧Tau≅1/(2π f u ) (3)
[0055] or with (2)
t sy ≧53 T (4)
[0056] Thus the synchronisation sequence must be at least 53 bits long; in practice t sy is extended to 100 bit (or 10 ns).
[0057] In optical packet transmission level jumps (intensity jumps) between the packets must be expected as the packets come from different sources. After a large i.e. powerful packet with power P max , the receiver requires time t gb to detune to a lower level of a possible smallest packet with power P min .
P min /P max ≅exp(− t gb /Tau) (5)
[0058] As a result and taking into account (3)
t gb ≅53 T ln( P max /P min ) (6)
[0059] The power ratio in dB: (10 times decimal logarithm)
R= 10 lg( P max /P min) (7)
R= 10 ln( P max /P min) /In 10
[0060] From (6) and (7) we get:
t gb ≅12.3 T*R (8)
[0061] This formula means:
[0062] with the same packet power (R=0) no guard band is required (t gb =0).
[0063] with an assumed power fluctuation R≦7 dB we get
t gb ≧87 T (9)
[0064] As estimate R≦7 dB is arbitrary, a reserve is established, e.g. t gb ≧100 T, or better a clearer reserve with t gb ≧200 T, or t gb ≧20 ns.
[0065] In order to achieve the theoretical limit values t gb and t sy , to reach a minimum channel utilisation E, from (1) we conclude
E=t pay /(12.3 T R+ 53 T+t pay ) (10)
[0066] where the time of payload t pay arises from the number of data payload bits N times bit duration T: t pay =N*T. Inserted in (10) and converted to N we get:
N≧ (12.3 R+ 53) E /(1 −E ) (11)
[0067] With a required utilisation of at least 95% (E=0.95) N≧2700 bit. The data payload per packet must therefore be longer than 2700 bit, otherwise 95% utilisation cannot be achieved. Taking into account technical supplements on t gb and t sy to 200 T or 100 T (see above), the minimum length is N≧5700 bit.
[0068] In the method according to the invention it is assumed that the data was originally present as NRZ signals.
[0069] The method according to the invention for synchronous transmission of data packets in telecommunication networks will now be explained below, where the data payload to be transmitted is embedded in a frame structure according to standard G.709.
[0070] In WDM systems (WDM: wavelength multiplexer technology) switching methodes in network nodes are performed on the basis of the WDM channels. This however has the disadvantage that the granularity of these channels depends on the bit rate used, which can be up to 40 GBit/s. Thus it is difficult to construct close-mesh data transport networks as some connections will be utilised to an extremely low extent.
[0071] A solution in the state of the art is “burst switching”, see Nishizawa et al, idem., for which however a totally new protocol must be created which involves numerous format changes.
[0072] The better solution to this problem according to the invention is the introduction of “virtual wavelengths” in standard G.709 (on standard G.709, see FIG. 1 a , 1 b bottom and ITU-T G.709, February 2001). Bits defined at present as reserve or experimental in data frame structure G.709 can be used to distinguish different virtual wavelengths. The transport functions must then observe these virtual wavelengths, for example the monitor functions are performed individually for each virtual wavelength. The virtual wavelengths can be both of constant and variable bandwidth.
[0073] By the definition or structure of transport signals according to the invention it is possible to add easily a switching function to an optimum connection element (=a network node) which allows switching on the basis of virtual wavelengths.
[0074] A switch device according to the invention is shown in FIG. 2 (see below). The line cards on the transmitter side fulfil the following functions:
[0075] FEC control calculations where available (FEC: forward error correction);
[0076] Adaptation of external data format (to standard G.709, “external frame structure”) to the internal data format (modified standard G.709 according to the invention, “internal frame structure”), in detail:
[0077] Rejection of the FEC field. This is superfluous as no transmission errors are possible within the switch.
[0078] Addition of a “burst overhead” and guard band for safe switching and reception of data signals.
[0079] The burst overhead contains at least one synchronization sequence, typically a sequence of 010101 . . . bits.
[0080] Standard G.709 and hence also the internal frame structure can be switched as a whole or in four part sections as the FEC field is also switched in four part sections, each of which is 256 Bytes long. This second possibility offers increased flexibility. As well as the phase (bit) synchronization sequence however, in this case a bit position (slot) synchronization sequence must also be added to the data signal as the corresponding synchronization sequence of G.709 frame structure (frame alignment overhead) is not available: this is only available in the first data row.
[0081] The reading of a table to establish to which output the virtual wavelength should be switched and whether the virtual wavelength should be changed;
[0082] Sending a request signal to a scheduler which controls the status of the switch matrix. The switch matrix passes the signals from one of its inputs to one of its outputs;
[0083] Storage of the internal frame structure i.e. the data packet until the scheduler releases the internal frame structure.
[0084] On the receiver side the line cards fulfil the following functions:
[0085] Reception of internal frame structures (data packets) in burst mode;
[0086] Removal of the internal data overhead;
[0087] Recalculation of FEC field if necessary, and
[0088] Transmission of data signal (i.e. the recreated outer frame structure) to the outer connection i.e. finally to the next network node or definitive recipient.
[0089] The task of the switch matrix is to switch the internal data structures precisely during the guard band times to avoid any type of data distortion. The internal use of the FEC field as an overhead has the advantage that no increase in transmission speed (speed up) is required, i.e. no different time systems need be noted.
[0090] In the connecting point the internal frame structure can be switched in burst mode i.e. a precise phase synchronization of all line cards is not required.
[0091] The synchronous method of signal transmission according to the invention allows the use of burst-mode-specific benefits without the entire network having to operate in burst mode but just part of the network node. The close correlation of the internal data format to the standard format G.709 is also advantageous.
[0092] [0092]FIG. 1 a shows a frame structure according to the original G.709 standard. The view shows the numbered columns 11 and rows 12 of Bytes of the G.709 data packet. The first row begins with a synchronization sequence of frame structure 13 (frame alignment overhead), followed by the optical transport unit overhead (OTUk overhead) 14 . In rows 2 to 4 these two areas 13 , 14 are replaced by the optical data unit overhead (ODUk overhead) 15 . In all four rows this is followed by the optical payload unit overhead (OPUk overhead) 16 followed by the data payload (OPUk payload) 17 . All rows then conclude with a section of the forward error correction (FEC) 18 .
[0093] The transmission sequence of data of such a frame structure is shown diagrammatically in FIG. 1 b . Transmission is in rows starting with the first row in the first column and then following the row sequence of the column entries. On completion of the first row, transmission of the second row, starting with its first column, continues in the direction of arrow 19 until the entire frame structure has been methoded.
[0094] [0094]FIG. 2 shows a network node 21 which works with the method according to the invention for synchronous data transmission. Several inputs 22 lead to the set of line cards 23 on the transmitter side. On arrival of a data packet to standard G.709 at one of the line cards 23 , the line card concerned passes a message to scheduler 24 and methodes the external frame structure into the internal frame structure according to the invention. Avoiding collisions and maintaining the minimum guard band of 20 ns, the scheduler now releases the internal frame structure to the matrix which was set by the scheduler according to the destination of the data packet, so that the internal frame structure is passed on to the corresponding line card of the set of line cards 26 on the receiver side. The original data format is recreated there and passed to the corresponding output line of output 27 of network node 21 .
[0095] [0095]FIG. 3 shows the internal frame structure 30 and 41 as generated by the transmission-side line card from the incoming data packet of format G.709. Frame alignment overhead 33 , OTUk overhead 34 , ODUk overhead 35 , OPUk overhead 36 and ODUk payload 37 are arranged as in standard G.709, see FIG. 1 a . Instead of FEC 18 there is a guard band 38 and an internal overhead 39 , where the guard band 38 extends over all rows, the internal overhead 39 however only over the first three rows. The internal overhead 39 , also known as a “burst overhead”, thus indicates a subsequent data section of the type of a second to fourth row and can be used for synchronization, whereas omission of the internal overhead 39 corresponds with the start of a new internal frame structure. The final section 40 in FIG. 3 of the upper internal frame structure 30 is then already allocated to the lower internal frame structure 41 at which transmission continues according to arrow direction 42 . The lower internal frame structure 41 is similar in structure to the upper internal frame structure 30 . | A method for the asynchronous transmission of data packets in telecommunication networks with a bit rate B is characterized by methoding of the data to be transmitted such that the probability of the occurrence of a 0 or 1 state in the data stream at each bit position is approximately equal and independent of other bit positions (=scrambling); waiting for a guard band time t gb , transmission of a synchronization sequence during time t sy , transmission of a synchronization word during time t co , and transmission of the data payload; detection of a synchronization sequence and synchronization to this in a receiver; detection of the start of the data packet by detection of the synchronization word in the receiver; reception of the data payload in the receiver. | 7 |
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